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Dr i v e 1 3

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Drive 13

Job No.

Removal and of poly V-belt 13 342

of poly V-belt and tensioner 343

Removal, and of poly V-belt tensioner

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Caution!

Check poly V-belt section and tenstoner for

damage and replace required.Do not use belt wax or lubricant.

Check seating of poly V-belt.

Poly V-belt dimensions

Poly V-belt layoutLength of poly V-belt in mm

602 I - 2030 2100

603 2080 2 14 5 ( 2 12 0) ' )

Up t o

603970

Note

Engine 602

Poly V-belt of different material and revised

design.

1310

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Engines 602.91 and 602.961

Poly V-belt drive) provided by additional

manufacturer (Gates).

n ot r e c o r d e d

Special tools

00 1 589 72 21 00

0 0

Removal

1 0 3 5 89 0 1 09 00

20

1 Remove radiator one-piece fan shroud

on engine 602.911 in model 201 (20-420).

2 On engine 602 in model 201 divided

fan shroud, open and remove, by taking out

(1) and turning ring (2) to the left.

Place on the fan, pull out housing (3) and

remove ring.

1 3. 1 0

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3 On engines 602 and 603 in model 124

Detach fan shroud and lay on the fan. Unscrew

Viscofan fan and remove fanshroud.

Use screw 103 589 01 09 00 and

steady 603 589 00 40 00 order to detach and

tighten up the hexagon socket bolt for the

Viscofan coupling.

4 On the engine 603.96 (TURBO) the

fan coupling cannot be removed

removing the radiator.

5 Detach by unscrewing nut (378).

Put a lever( 12 13 mm dia., approx. 300 mm

long) or wrench from tool the

hole the tension lever (374). Press

lever slightly to the left, bolt (375) can be

slid back the of the manifold.

Release tension by swinging lever

to the

Remove poly V-belt, by pressing back the

pulley.

Check poly V-belt section and tensioner for

damage and replace required

(e.g. worn bearing on tensioner, dents

pulley etc.).

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Putting on poly V-belt

Caution!

Do not use any belt wax or similar products.

6 pulley slightly. Turn poly V-belt on

the back, form a small loop and slide between

coolant pump pulley and crankshaft pulley.

7 Press poly V-belt with the left handonto coolant pump pulley and turn this to the left

(arrow) poly V-belt up onto idler pulley.

8 Put poly V-belt on pulley and crankshaft

pulley. Then rotate the free part of poly V-belt

and place onto the refrigeration compressor,

power steering pump, coolant pump and

alternator pulley.

9 Tension poly V-belt and install tensioner.

13 .10

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11 Check of poly V-belt on the pulleys.

12 engine 602 in model 124 install fan orViscofan coupling with fan and fan shroud.

torque of Viscofan coupling bolt

45 Nm.

Use steady 603 589 00 40 00 for up.

13 On engine 602.911 in model 201 Install

radiator (20-420) without fan shroud.

B Pulley layout on vehicles power steering

Length of belt

Engine 602: 2030 mm

Engine 603: 2080 mm

1 Idler pulleyCrankshaft

5 Alternator

Power steering pump

8 Coolant pump

C Pulley layout on vehicles with power steering

and refrigeration compressor

Length of belt

Engine 602: 2100 mm

603: 2145 mm

Engine 603.970: 2120 mm

1 Idler pulley

2 Crankshaft

3 compressor

5 Alternator

Power pump

8 Coolant pump

13.10

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A. V-belts

The poly V-belt IS to be replaced one of the

damaged patterns is

testing.

Damage pattern

C Lumps of rubber base of

of or stones.

Flank wear

F Ribs are

E New poly V-belt are trapezoidal.

G Strand base of (lighter points).

K Strand torn out sideways.

L Outer strands frayed.

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Rib detached from base of belt (arrow).

Transverse cracks in and or

J Rib fracturesJ J

I

Transverse cracks in several ribs.

M Transverse cracks on the back.

1 3 . 1 0

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Special tools

Model 124 and 126Connect compression pressure plotter

001 589 78 21 00, by separating plug connection

(X 27) at the left compartment wall and

connect connector lead (04) of the compression

pressure plotter to the plug (terminal 50) with

adapter lead 124 589 36 63 00 (05).

Model 12 4

Model 126

Model 201

2 Connect compression pressure plotter

001 589 78 21 00, by plug connector

(X 27) at left front wall and connect the connec-

tor lead (04) of compression pressure plotter to

the plug (terminal 50) with adapter lead

124 589 36 63 00.

13 Model

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3 Connect up second connector lead of the

plotter to positive terminal

30) of the battery.

4 Mark poly V-belt chalk at a clearly

point (arrow).

5 Turn increments and check poly

belt for damage.

Complete process when marking is

(one complete belt revolution).

1 3. 1 0

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The following parts are to be checked on the

tension lever bearing (1 st design up to 10 85):

6 Check bearing (30) of tension lever (360)

for firm seating.

Note

The collar of bearing (30) must contact the

case cover (28). The pulley must not

have any problems.

7 Check tensioner bearing bush.

Note

The pulley must not any alignment

faults. The bearing bushes are worn when there

IS a detectable play between the (30)

and tension lever (360).

3 5 5

35 7

3 5 6

37 0

3 6 1

3 6 0

3 6 8

3 6 5

1 3. 1 0

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Special tools

001 589 66 21 0 0 00 1 589 72 21 00

00 0 0

Note

Idler pulleys on vehicles without power steering

have grooves for the of the poly V-belt the

running surface.

Idler pulleys have flat surfaces.

Color marking of tension spring:

power pump, blue.

1 3 . 1 0

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370

361

3 6 0

0059 15

3 6 8

3 6 5

Tension lever

28 cover

30a Dowel screw

360 lever

362 Angular ball

363 Washer

368 cap

Production breakpoint:

124.133 6 0 3 . 9 6 2

I

000016 from start of

124.193

recorded

Engine 602

Single-acting damper for belt tensioner,

double-acting.

13.10

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Production breakpoint:

Between 07 89 and 09 89 and from 06 90 the

dampers for the tensioner have lower

rubber

Pressed-on rubber bearing

rubber

Vehicle end No.

306516 237404

13 10

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Production breakpoint:

03 90 bolts for the power

pump have been hot galvanized,

phosphated, for Improved surface protection.

EXIT