Remove/install belt pulley/vibration damper

AR03.30-G-1600CI

Remove/install belt pulley/vibration damper

05.09.2018

Engine

541.9, 542.9, 941.9, 942.9 in model 000.001

Without electromagnetic viscous fan clutch, Behr

Engine

541.9, 542.9, 941.9, 942.9 in model 000.001

Without electromagnetic viscous coupling for fan

Engine

541.9, 542.9, 941.9, 942.9 in model 000.001

Without electromagnetic fan drive (Linnig coupling)

Engine

541.9, 542.9, 941.9, 942.9 in model 000.001

Without high-speed fan drive with belt drive

Modification notes

05.09.2018

Work procedure completely modified.

Shown on expansion reservoir on cooler (1)

1

Radiator

3

Adapter

5

Vibration damper

2

Fan

4

Poly-V belt for alternator

6

Slinger

5

Vibration damper

7

Drift

 Warning

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

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1

Remove fan (2).

AR20.40-G-5614CI

2

Slacken alternator poly-V-belt (4) and remove from the alternator belt pulley.

Routing diagram

AR13.22-G-3902-02CI



Damage profiles for a poly-V belt

AP13.22-D-1351-01A

 Installation: Observe the routing diagram.

 Check alternator poly-V-belt (4) for wear and damage.

If damage or wear can be detected,



replace alternator poly-V-belt (4).

AR13.22-G-0003CI

3

Attach turning device for engine and block engine.

AR03.30-G-1600-03CH

 Block engine by inserting the pin in the  turning device.

 Bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01K

 Bolt, turning device to timing case

*BA01.60-N-1009-01K

 Turning device

*904589046300

4

Remove two opposite screws from the vibration damper (5).

 Bolt, vibration damper to crankshaft

*BA03.30-N-1002-01R

 Socket wrench bit

*422589020900

5

Screw in drifts (7).

 Drift

*403589026300

6

Remove remaining screws from vibration damper (5).

 Installation: Tighten screws of the vibration damper (5) crosswise.

 Bolt, vibration damper to crankshaft

*BA03.30-N-1002-01R

 Socket wrench bit

*422589020900

7

Remove vibration damper (5) via the drifts (7).

8

Remove slinger (6).

 Installation: Observe installation position.
The slinger (6) must be installed with the flat side toward the vibration damper (5).



Check

9

Check vibration damper (5) and belt pulleys of the remaining driven component parts for damage and smooth operation.

If damage or bad smooth operation can be detected,



Replace corresponding component.

10

Install in the reverse order.

 Timing case

Number

Designation

Engine 541.9, 542.9, 941.9, 942.9 in model 000.001

BA01.60-N-1001-01K

Bolt, cap of TDC inspection hole to timing case

Nm

25

 Timing case

Number

Designation

Engine 541.9, 542.9, 941.9, 942.9 in model 000.001

BA01.60-N-1009-01K

Bolt, turning device to timing case

Nm

25

 Flywheel, drive plate, vibration damper, starter ring gear

Number

Designation

Engine 541.9, 542.9, 941.9, 942.9 in model 000.001

BA03.30-N-1002-01R

Bolt, vibration damper to crankshaft

Nm

200