Removing and installing belt pulley/vibration damper - RA03001203420X(03-3420)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Preceding work:

Bottom engine compartment panel removed

(Maintenance Manual 2, Op. no. 6190).

Viscous fan clutch removed (20-3120) .

Operation no. of operation texts and work units or standard texts and flat rates 03-1320-1911

Fig 1: Identifying Vibration Damper, Fan And Coolant Pump

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Ground cable at battery	disconnect, connect.
Guard plate	attach in front of radiator.
Crankshaft of cylinder 1	rotate to TDC (step 3).
Bolts of belt pulleys of fan (10) and of coolant pump (9)	slacken, tighten (13 Nm) (step 4).
Poly V-belt	remove, install (13 -3420).
Tensioning pulley (8) of poly V-belt	remove, install (38 Nm) (step 6).
Belt pulleys of fan (10) and of coolant pump (9)	remove, install (step 7).
Retaining lock for crankshaft/ring gear	remove, install (03-5000) .
Bolt of hub (1)	unscrew, screw on (step 9).
Belt pulley/vibration damper (6)	remove, install (step 10).
Woodruff key (7)	note.
Belt pulley (6)	check.

DATA IN MM

Permissible deviation at vibration damper

radial runout ⁽¹⁾

0.2

lateral runout ⁽²⁾

0.3

⁽¹⁾	Measured at pulley, inside front.

⁽²⁾	Measured at pulley, front.

TIGHTENING TORQUES IN NM

Bolt at crankshaft	400
Bolt of belt pulley of fan and coolant pump	13
Bolt of tensioning device	38

Special tools

Fig 2: Identifying Special Tools (602 589 00 40 00 03)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tools (001 589 74 21 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Special Tools (001 589 72 21 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Special Tools (001 589 65 09 00 03 07 32)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOL

3/4" square socket to 1/2" external square connector

eg.

Hazet, D-5630 Remscheid Order no. 1058 RI

SHOP-MADE TOOL

Guard plate for radiator/condenser

Dimensions: approx. 680 X 400 X 1

Disconnect ground cable at battery.
Attach guard plate in front of radiator.
Rotate crankshaft until cylinder 1 is at TDC (arrow) so that the Woodruff key in the crankshaft is facing vertically up.

Fig 6: Locating Cylinder 1 At TDC Position
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Slacken bolts (arrows) of the belt pulleys of the fan (10) and of the coolant pump (9).
Remove poly V-belt (13 -3420).

Fig 7: Locating Fan & Coolant Pump Belt Pulleys Bolts
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew bolt (1), remove tensioning pulley (8) of poly V-belt.
Tightening torque 38 Nm.

Fig 8: Locating Poly V-Belt Tensioning Pulley Bolt
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unbolt belt pulleys of fan (10) and of coolant pump (9) and remove.

Fig 9: Locating Belt Pulleys Of Fan And Of Coolant Pump
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert retaining lock for crankshaft/ring gear (03-5000) .

Fig 10: Locating Retaining Lock For Crankshaft/Ring Gear
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew bolt of hub.
Installation note

Oil bolt thread and 4 dished washers. Fit on dished washers with curved side facing bolt head. Tighten bolt to 400 Nm.

Fig 11: Identifying Curved Side Facing Bolt Head
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove belt pulley (5) together with vibration damper (6).
Installation note

Align Woodruff key (7), fit on vibration damper (6) and determine by turning whether the slot of the hub (3) is engaged with the Woodruff key (7) in the crankshaft (11).
Check belt pulley.
Install in the reverse order.

Fig 12: Identifying Vibration Damper, Woodruff Key And Crankshaft
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.