2003-2009 Mercedes-Benz CLK Class C209 Service & Repair Manual

SERVICE AND REPAIR MANUAL

HVAC Air Compressor, Belt Drives - 209 Chassis TESTING & REPAIR TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9112AB ENGINE 112 TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9113AB ENGINE 113 Remove, install poly V- belt ENGINE 112, 113... AR13.22-P-1202B Remove, install poly V- belt ENGINE 112, 113... AR13.22-P-1202BA Remove, install poly V- belt ENGINE 112, 113... AR13.22 - P - 1202PV Remove, install poly V- belt ENGINE 112, 113... AR13.22-P-1202R Remove, install poly V- belt ENGINE 112.947 in MODEL 170.465 AR13.22-P-1202SV Remove, install poly V- belt ENGINE 112.960 in MODEL 170.466 ENGINE 112.961 in MODEL 203.065/265 AR13.22-P-1202SVK Remove/install generator poly-V-belt pulley ENGINE 104, 111, 112, 119, 601, 602, 604, 605, 606... AR13.22-P-5700EA Remove/install poly-V belt tensioning device ENGINE 112, 113... AR13.25-P-3200B Remove/install poly V- belt tensioning device ENGINE 112, 113... AR13.25 - P - 3200BA Remove/install poly-V- belt tensioning device ENGINE 112, 113... AR13.25-P-3200R Remove, install poly-V- belt for compressor ENGINE 113... AR13.21-P-1202RVK Remove, install poly-V- belt for compressor ENGINE 113.990 in MODEL 219.376 AR13.21-P-1202TZ

TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9156AB ENGINE 156 Remove, install poly V-belt ENGINE 112, 113... AR13.22-P-1202B Remove, install poly V-belt ENGINE 112, 113... AR13.22-P-1202BA Remove, install poly V-belt ENGINE 113.964 in MODEL 164.175 AR13.22-P-1202GZ Remove, install poly V-belt ENGINE 112, 113... AR13.22 - P - 1202PV Remove, install poly V-belt ENGINE 112, 113... AR13.22-P-1202R Remove/install poly V-belt ENGINE 113.971 in MODELS 251.075/175 AR13.22-P-1202RT Remove/install poly V-belt ENGINE 113.990 in MODELS 211.076 /276 AR13.22-P-1202RV Remove, install poly V-belt ENGINE 113.967 in MODEL 219.375 AR13.22-P-1202TY Remove, install poly V-belt ENGINE 113.990 in MODEL 219.376 AR13.22-P-1202TZ Remove/install poly-V belt tensioning device ENGINE 112, 113... AR13.25-P-3200B Remove/install poly V-belt tensioning device ENGINE 112, 113... AR13.25 - P - 3200BA Remove/install poly-V-belt tensioning device ENGINE 113.964 in MODEL 164.175 AR13.25-P-3200GZ Remove/install poly-V-belt tensioning device ENGINE 112, 113... AR13.25-P-3200R Removing/installing the poly-V-belt tensioning device ENGINE 113.971 in MODELS 251.075 /175 AR13.25-P-3200RT Remove/install poly V-belt tensioning device ENGINE 113.967 in MODEL 219.375 AR13.25-P-3200TY Remove/install poly-V-belt tensioning device ENGINE 113.990 in MODEL 219.376 AR13.25-P-3200TZ Remove/install tensioning device of compressor poly- V-belt ENGINE 113... AR13.25-P-3217RVK Remove/install tensioning device for compressor poly-V-belt ENGINE 113.990 in MODEL 219.376 AR13.25-P-3217TZ Remove/install poly V- belt ENGINE 156 in MODEL 164, 251 AR13.22-P-1202GZS Remove/install poly-V ENGINE 156 in MODEL AR13.22-P-1202SMG

TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9272AB ENGINE 272 belt 216, 221 Remove/install poly V- belt ENGINE 156.982 in MODELS 209.377 /477 ENGINE 156.983 in MODELS 211.077 /277, 219.377 AR13.22 - P - 1202TMG Remove/install poly-V belt tensioning device ENGINE 156 in MODEL 164, 251 AR13.25-P-3200GZS Remove/install poly-V belt tensioning device ENGINE 156 in MODEL 216, 221 AR13.25-P-3200SMG Remove/install poly-V belt tensioning device ENGINE 156.982 in MODEL 209.377 /477 ENGINE 156.983 in MODEL 211.077 /277, 219.377 AR13.25 - P - 3200TMG Remove/install components for belt drive ENGINE 272 in MODEL 204 AR13.20-P-0001CV Remove/install components for belt drive ENGINE 272, 273 in MODEL 164, 251 AR13.20-P-0001GZA Remove/install components of belt drive ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL 216 AR13.20-P-0001SX Remove/install components of belt drive ENGINE 272, 273 in MODELS 211, 219 AR13.20-P-0001TS Remove/install poly-V- belt guide pulley ENGINE 272, 273... AR13.21 - P - 3350QB Remove/install poly V- belt guide pulley ENGINE 272, 273 in MODEL 230 AR13.21-P-3350RX Remove/install poly V- belt guide pulley ENGINE 272.942 in MODEL 171.454 ENGINE 272.963 in MODEL 171.456 AR13.21-P-3350VA Remove/install poly V- belt ENGINE 272, 273... AR13.22 - P - 1202QB Remove, install poly V- belt ENGINE 272, 273 in MODEL 230 AR13.22-P-1202RX Remove, install poly V- belt ENGINE 272.942 in MODEL 171.454 ENGINE 272.963 in AR13.22-P-1202VA

TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9273AB ENGINE 273 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 MODEL 171.456 Remove/install poly-V- belt tensioning device ENGINE 272, 273... AR13.25 - P - 3200QB Remove/install poly V- belt tensioning device ENGINE 272, 273 in MODEL 230 AR13.25-P-3200RX Remove/install poly V- belt tensioning device ENGINE 272.942 in MODEL 171.454 ENGINE 272.963 in MODEL 171.456 AR13.25-P-3200VA Remove/install components for belt drive ENGINE 272, 273 in MODEL 164, 251 AR13.20-P-0001GZA Remove/install components of belt drive ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL 216 AR13.20-P-0001SX Remove/install components of belt drive ENGINE 272, 273 in MODELS 211, 219 AR13.20-P-0001TS Remove/install poly-V- belt guide pulley ENGINE 272, 273... AR13.21 - P - 3350QB Remove/install poly V- belt guide pulley ENGINE 272, 273 in MODEL 230 AR13.21-P-3350RX Remove/install poly V- belt ENGINE 272, 273... AR13.22 - P - 1202QB Remove, install poly V- belt ENGINE 272, 273 in MODEL 230 AR13.22-P-1202RX Remove/install poly-V- belt tensioning device ENGINE 272, 273... AR13.25 - P - 3200QB Remove/install poly V- belt tensioning device ENGINE 272, 273 in MODEL 230 AR13.25-P-3200RX

ENGINE 272.941 in MODELS 203.092 /292 ENGINE 273 in MODEL 209 Fig. 1: Identifying Poly - V - Belt Guide Pulley Components Courtesy of MERCEDES-BENZ USA 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 2 Remove front engine cover Pull front engine 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

COOLANT PUMP, COOLANT THERMOSTAT REMOVE, INSTALL POLY V-BELT - AR13.22-P-1202 Remove, install poly V-belt - AR13.22-P-1202PV ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461 ENGINE 112.946 in MODEL 203.064 /264 /764 ENGINE 113.968 in MODEL 209.375 /475 ENGINE 112.913 in MODEL 211.061 /261 ENGINE 112.949 in MODEL 211.065 /265 ENGINE 113.967 in MODEL 211.070 /270 ENGINE 113.987 in MODEL 209.376 /476 ENGINE 112.955 in MODEL 209.365 /465 ENGINE 112.916 in MODEL 203.081 /281 ENGINE 112.953 in MODEL 203.084 /284 ENGINE 112.917 in MODEL 211.080 /280 ENGINE 112.954 in MODEL 211.082 /282 ENGINE 113.969 in MODEL 211.083 /283 ENGINE 113.988 in MODEL 203.076 /276 ENGINE 113.989 in MODEL 171.473 Shown on engine 112 in model 203 Number Designation Engine 272 Engine 273 BA20.10-P-1004- 01U Bolt, poly-V-belt guide pulley at coolant pump Nm 35 35

Fig. 2: Identifying Poly V - Belt Components - Shown On Engine 112 In Model 203 Courtesy of MERCEDES-BENZ USA Remove 1 Loosen poly-V-belt (1) and remove Old version (A): Swivel stud bolt (2) at tensioning pulley (3) in an counter-clockwise direction. New version (B): Swivel tool mount for tensioning device (4) at tensioning pulley (3) in an counter- clockwise direction. Lock tensioning pulley (3) with pin or drift (diameter 5 mm). Check 2 Inspect belt pulley sections and tensioning device for damage and dirt 3 Check poly-V-belt (1) Check poly-V-belt in visible area for wear All except model 171.473 AP13.22 - P - 1352Z Model 171.473 AP13.22-P-1352VT Install 4 Fit on poly V-belt (1), tension Do not use belt wax or any similar

Remove/install poly V-belt - AR13.22-P-1202QB 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. 3: Identifying Poly V - Belt Components - Engine 272.920/940/941 Courtesy of MERCEDES-BENZ USA products. Start in numerical order of the relevant running diagram at tensioning pulley (3), see: ? Layout diagram of poly- V-belt AR13.22 - P - 3902 - 02B Removing Risk of injury caused by fingers being pinched or Keep body parts and limbs well clear of moving parts. AS00.00 - Z - 0011 - 01A

crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. 1 Open engine hood and raise to vertical position Model 203 AR88.40-P-1000P Model 209 AR88.40 - P - 1000Q 2 Remove front engine cover (1) Pull out the front engine cover (1) from the mounts. 3 Loosen poly-V-belt (2) and remove To do this, swivel tensioning device (3) in anti-clockwise direction at hexagon (4) (arrow). Remove the poly-V-belt (2) and slacken the tensioning device (3). Checking 4 Inspect belt pulley sections, tensioning device (3) and guide pulleys (5) Check for wear, damage or soiling and replace if necessary: ? Remove/install poly V- belt tensioning device AR13.25 - P - 3200QB Remove/install poly-V- belt guide pulley AR13.21 - P - 3350QB 5 Check poly-V belt (2) and replace if required Check poly-V-belt in visible area for wear Model 203, 209 with engine 272 AP13.22 - P - 1352PIT Model 209 with engine 273 AP13.22 - P - 1352RX Install 6 Mount poly-V-belt (2) and tension it. To do this, swivel tensioning device (3) in anti-clockwise direction at hexagon (4) (arrow). Mount poly-V-belt (2) as shown on routing diagram and release tensioning device (3). Routing diagram of poly V-belt Do not use wax or similar products, as this AR13.22 - P - 3902 - 02VA

2003-2009 Mercedes-Benz CLK Class C209 Service & Repair Manual

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