Remove/install belt pulley/vibration damper

AR03.30-W-1600B

Remove/install belt pulley/vibration damper

3.3.09

15.3.05

Work procedure completely revised.

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Danger!

Risk of injury caused by being caught or pinched as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A

1

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

2

Remove trim panel in front of radiator (1)

3

Remove side soundproofing from engine on left, right and rear

4

Detach coolant expansion reservoir from radiator and put to one side

 Do not separate coolant lines.

5

Remove red charge air hose



*BA09.41-N-1006-01C

6

Detach oil dipstcik guide tube and oil filler pipe at radiator (1)

7

Remove black charge air hose at charge air cooler



*BA09.41-N-1006-01C

8

Unscrew bolts at the radiator mounting (2) on right and left and press radiator (1) to the front

 Fix radiator (1) on right and left with spacers (arrow).

9

Remove soundproofing below the radiator (1).

10

Detach fan wheel (4) with viscous fan clutch (3) at intermediate piece (5)

 Secure fan wheel (4) with viscous fan clutch (3) at the radiator shroud.



*BA20.40-N-1001-01C

11

Detach intermediate piece (5) from the belt pulley/vibration damper (7) and remove upwards

 At the same time press the radiator (1) at the top towards the front.



*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

12

Release the tension on the poly-V-belt of the alternator (6) and remove from alternator belt pulley

 Installation: Inspect condition of poly-V-belt of alternator (6), replace if necessary.

Observe poly-V-belt routing plan.

AR13.22-W-3902-02A



Damage patterns of poly V-belt

AP13.22-D-1351-01A

13

Take off end cover at timing case



*BA01.60-N-1001-01B

14

Attach turning device to timing case



*407589006300



*BA01.60-N-1009-01B

15

Block engine with turning device

16

Undo the two opposite bolts at the belt pulley/vibration damper (7)



*422589020900



*BA03.30-N-1002-01F

17

Screw in the drifts (9)



*403589026300

18

Unscrew the remaining bolts at the belt pulley/vibration damper (7) and remove the belt pulley/vibration damper (7) via the drifts (9)

 Installation: Check the belt pulley/vibration damper (7) 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

19

Take off slinger (8)

20

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 the running engine

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

AS00.00-Z-0005-01A

21

Crank engine and check crankshaft radial sealing ring for leaks

Number

Designation

Engines
541.9, 542.9

BA01.60-N-1001-01B

Bolt connecting end cover of TDC inspection hole to timing case

Nm

25

BA01.60-N-1009-01B

Bolt connecting engine turning device to timing case

Nm

25

Number

Designation

Engines 541.9, 542.9

BA03.30-N-1002-01F

Bolt connecting vibration damper to crankshaft

Nm

200

Number

Designation

Engine 541.9

Engine 542.9

BA09.41-N-1006-01C

Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler

Nm

7.5

7.5

Number

Designation

Engines
541.9, 542.9 without
Code ML1,
ML3, MZ5, MZ3, MO1

BA20.40-N-1001-01C

Bolt connecting viscous fan clutch to intermediate piece

Nm

50

BA20.40-N-1008-01C

Bolt connecting intermediate piece to crankshaft vibration damper

Nm

30