2004 Mercedes-Benz C-Class C240 (W203) Service & Repair Manual

W203 MERCEDES SERVICE AND REPAIR MANUAL

2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis TESTING & REPAIR REMOVE/INSTALL POLY-V-BELT FOR COMPRESSOR - AR13.21-P-1202A ENGINE 111.943 /973 in MODEL 170 ENGINE 111.944 /975 in MODEL 202, 208 ENGINE 111.947 in MODEL 210 ENGINE 111.955 in MODEL 203 Fig. 1: Identifying Poly - V - Belt For Compressor Remove/Install Components - Engine 111.955 Removing 1 Remove viscous fan clutch (26) Vehicles fitted with viscous fan clutch Left-hand thread AR20.40-P-5660A 2.1 Remove fan shroud Vehicles with fan cowl AR20.40-P-6800HA 2.2 Remove electric fan Vehicles fitted with electric fan AR20.40 - P - 5000PR 3 Loosen poly-V-belt (10) Swivel tensioning arm (2) and tensioning pulley (3) in counterclockwise Fig. 2 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

MULTI-BELT DRIVE direction at stud bolt (4, external Torx E10) for this step. Do not swivel tensioning arm (2) against tensioning pulley the nut. 4 Remove poly-V-belt (10) Checking 5 Inspect belt pulley sections and tensioning device for damage and dirt. 6 Check poly-V-belt (10) Check poly-V-belt in visible area for wear AP13.22-P-1352Z Install 7 Fit on poly-V-belt (10), then clamp Do not use belt wax or any similar products. In numerical order of relevant running diagram, beginning at tensioning pulley ? Routing diagram of poly-V- belt AR13.21 - P - 3902 - 02A Poly-V-belt dimensions *BE13.21-P-1001-01A The position marking (B) visible from the underside of the engine, must be positioned within the working range (A). If this is not the case, inspect length of poly-V-belt and also tensioning device Fig. 2 8.1 Install fan shroud Vehicles with fan cowl AR20.40-P-6800HA 8.2 Install electric fan Vehicles fitted with electric fan AR20.40 - P - 5000PR 9 Install viscous fan clutch (26) Vehicles fitted with viscous fan clutch Left-hand thread AR20.40-P-5660A Number Designation Engine Engine Engine 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

MULTI-BELT DRIVE Fig. 2: Identifying External Torx Set (001 589 76 09 00) REMOVE, INSTALL POLY-V-BELT FOR COMPRESSOR - AR13.21-P-1202PK ENGINE 111.955 in MODEL 203.045 /245 /745 111.943/944/947/973/975 without AC compressor with power steering pump 111.944/947/975 without AC compressor with tandem pump 111.943/944/947 973/975 with AC compressor with power steering pump BE13.21- P-1001- 01A Length of belt of compressor drive mm 1330 1330 1330 Number Designation Engine 111.944/947/975 with AC compressor with tandem pump Engine 111.955 with AC compressor with power steering pump BE13.21-P-1001- 01A Length of belt on compressor drive mm 1330 1355 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

Fig. 3: Identifying Poly - V - Belt For Compressor Remove/Install Components - Engine 111.955 In Model 203.045 /245 /745 Remove 1 Remove air filter housing AR09.10 - P - 1150PK 2 Loosen poly-V-belt (1) and remove Swivel stud bolt (2) at tensioning pulley (3) in anti-clockwise direction (arrow) for this step. Checking 3 Inspect belt pulley sections and tensioning device for damage and dirt, replace if necessary 4 Inspect poly V-belt (1), replace if necessary Check poly-V-belt in visible area for wear AP13.22-P- 1352Z Install 5 Fit on poly V-belt (1), tension Installation: Do not use any belt wax or similar products Fit on poly V-belt as specified in running diagram ? Running diagram of poly V-belt. AR13.22 - P - 3902 - 02PR 6 Install air filter housing Installation: Lightly coat rubber retainer with antifriction agent. AR09.10 - P - 1150PK 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

REMOVE/INSTALL POLY-V-BELT GUIDE PULLEY - AR13.21-P-3350QB ENGINE 272.920 in MODELS 203.052 /252 /752 ENGINE 272.940 in MODELS 203.054 /254, 209.354 /454 ENGINE 272.960 in MODELS 203.056 /256 /756, 209.356 /456 ENGINE 272.970 in MODELS 203.087 /287 ENGINE 272.941 in MODELS 203.092 /292 ENGINE 273 in MODEL 209 Fig. 4: Identifying Poly - V - Belt Guide Pulley Remove/Install Components Remove/install Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. Keep body parts and limbs well clear of moving parts. AS00.00 - Z - 0011 - 01A Notes on self-locking nuts and bolts AH00.00 - N - 0001 - 01A 1 Open engine hood and raise to vertical position Model 203 AR88.40 - P - 1000P Model 209 AR88.40-P- 1000Q Pull front engine 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

COOLANT PUMP, COOLANT THERMOSTAT POLY V-BELT RUNNING DIAGRAM, MULTI-BELT DRIVE - AR13.21-P-3902-02A Running diagram of basic drive (6-groove) Fig. 5: Running Diagram Of Basic Drive (6 - Groove) Running diagram of compressor drive (6-groove) Fig. 6: Running Diagram Of Compressor Drive (6 - Groove) REMOVE/INSTALL POLY V-BELT - AR13.22-P-1202A ENGINE 111 2 Remove front engine cover cover upward and out of mountings. 3 Remove poly-V-belt AR13.22 - P - 1202QB 4 Lever off covers (1b, 2b) 5 Remove bolts (1a, 2a) *BA20.10 - P - 1004 - 01U 6 Remove guide pulleys (1, 2) 7 Install in the reverse order Number Designation Engine 272 Engine 273 BA20.10-P-1004-01U Bolt, poly-V-belt guide pulley at coolant pump Nm 35 35 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

Fig. 7: Identifying Poly V - Belt Remove/Install Components (Engine 111) Removing 1.1 Remove viscous fan clutch (26) Engines with viscous fan clutch 0046 Left-hand thread AR20.40-P-5660A 1.2 Remove electric fan Engines fitted with electric fan AR20.40 - P - 5000PR 2 Remove poly V-belt of compressor (10) Engine 111 with compressor AR13.21 - P - 1202A 3 Loosen poly-V-belt (11) Swivel tensioning arm (2) and tensioning pulley (3) in counterclockwise direction at stud bolt (4, external torx E10) for this step. Do not swivel tensioning arm (2) against the nut attaching the tensioning pulley. Fig. 2 4 Take off poly V-belt (11) Checking 5 Inspect belt pulley sections and tensioning device for damage and dirt. 6 Inspect poly V-belt (11) Check poly-V-belt in visible area for wear Except engine 111.977 AP13.22-P-1352Z Engine 111.977 AP13.22-P-1351GH Install 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

MULTI-BELT DRIVE MULTI-BELT DRIVE 7 Fit on poly-V-belt (11), then clamp Do not use belt wax or similar products. In numerical order of relevant running diagram, beginning at tensioning pulley ? Running diagram of poly V-belt of engines not fitted with compressor AR13.22 - P - 3902 - 02A Running diagram of poly V-belt of engines fitted with compressor AR13.21 - P - 3902 - 02A Poly V-belt dimensions of engines not fitted with compressor *BE13.22 - P - 1001 - 01B Poly V-belt dimensions of engines fitted with compressor *BE13.21 - P - 1002 - 01A The position marking (B) must be positioned within the working range (A). If this is not the case, inspect the length of the poly V-belt and also the tensioning device Fig. 2 8 Install poly V-belt of compressor Engine 111.943/944/947/973/975 AR13.21 - P - 1202A 9.1 Install viscous fan clutch (26) Engines with viscous fan clutch Left-hand thread AR20.40-P-5660A 9.2 Install electric fan Engines fitted with electric fan AR20.40 - P - 5000PR Number Designation Engine 111.943/944/947/973/975 without AC compressor with power steering pump Engine 111.943/944/947/973/975 with AC compressor with power steering pump Engine 111.944/944/947 without AC compressor with tandem pump BE13.21- P-1002- 01A Length of belt of base drive mm 1775 1875 1760 Number Designation Engine 111.944/947/975 with AC compressor with tandem pump Engine 111.955 with AC compressor and with power steering pump Engine 111.958/983 BE13.21-P- 1002-01A Length of belt of base drive mm 1860 1860 1870 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

SINGLE-BELT DRIVE Fig. 8: Identifying External Torx Set (001 589 76 09 00) REMOVE/INSTALL POLY V-BELT - AR13.22-P-1202PK ENGINE 111.955 in MODEL 203.045 /245 /745 Fig. 9: Identifying Poly V - Belt Remove/Install Components - Engine 111.955 In Model 203.045 /245 /745 Number Designation Engine 111 except 111.944/947/975 without AC compressor Engine 111 except 111.944/947/975 with AC compressor Engine 111 except 111.943/944/947/973/975 without AC compressor with VDA power steering pump Engine 111 except 111.943/944/947/973/975 with AC compressor with VDA power steering pump BE13.22- P-1001- 01B Belt length mm 2040 2140 2055 2155 Remove AR13.21-P- 2007 Mercedes-Benz C230 2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis

2004 Mercedes-Benz C-Class C240 (W203) Service & Repair Manual

You're Reading a Preview

Recently Viewed