Remove/install belt pulley/vibration damper

AR03.30-W-1600BB

Remove/install belt pulley/vibration damper

12.12.08

15.3.05

Work procedure completely revised.

 

Remove/Install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove radiator (1)

AR20.20-W-3865B

2

Remove electromagnetic fan clutch (3)

AR20.40-W-5616A

3

Detach intermediate flange (4) on belt pulley/vibration damper (6)



*BA20.40-N-1008-01C

 Danger!

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under load

Use only approved tensioning devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

4

Release the tension on the poly-V-belt of the alternator (5) and take if off the belt pulley of the alternator

 Installation: Check the condition of the poly-V-belt of the alternator (5), replace it if required.

Observe poly-V-belt routing plan.

AR13.22-W-3902-02A



Damage patterns of poly V-belt

AP13.22-D-1351-01A

5

Take off end cover at timing case



*BA01.60-N-1001-01B

6

Attach cranking device to timing case



*407589006300



*BA01.60-N-1009-01B

7

Block engine with rotating device

8

Undo the two opposite bolts at the belt pulley/vibration damper (6)



*422589020900



*BA03.30-N-1002-01F

9

Screw in the drifts (8)



*403589026300

10

Unscrew the remaining bolts at the belt pulley/vibration damper (6) and remove the belt pulley/vibration damper (6) via the drifts (8)

 Installation: Check the belt pulley/vibration damper (6) and the belt pulleys for the remaining driven parts for damage and smooth running, if necessary, replace any affected part(s)



*422589020900



*BA03.30-N-1002-01F

11

Remove slinger (7)

12

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near engine

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

13

Crank the engine and check the crankshaft radial sealing ring for leaks

Number

Designation

Engines
541.9, 542.9

BA01.60-N-1001-01B

Bolt of end cover of TDC inspection hole to timing case

Nm

25

BA01.60-N-1009-01B

Bolt of engine cranking device to timing case

Nm

25

Number

Designation

Engines
541.9, 542.9

BA03.30-N-1002-01F

Bolt, vibration damper to crankshaft

Nm

200

Number

Designation

Engine
541.9, 542.9 with code MZ5

BA20.40-N-1008-01C

Bolt, intermediate piece to crankshaft vibration damper

Nm

30