Procedure
A. CHECK PART NUMBER OF HARMONIC BALANCER PULLEY
1. Turn crankshaft in direction of normal rotation until the part number (arrow, Figure 1) of the harmonic balancer pulley is visible.
2. If the harmonic balancer pulley has one of the part numbers listed below, it must be replaced (for replacement procedure refer to next step):
Note:
ONLY these 2 part numbers (below) require replacement.
^ A112 035 00 00
^ A112 035 06 00
3. Replacement procedures for harmonic balancer pulley:
^ Engines 112 and 113 with viscous engine fan (non AMG models) refer to subject B.
^ Engines 112 and 113 with electric engine fan (non AMG models) refer to subject C.
B. ENGINES 112 AND 113 WITH VISCOUS ENGINE FAN
1. Remove lower engine cover (only on model 163.172) refer to WIS: AR61.20-P-1105GH.
2. Remove front air filter cover or engine cover (as necessary).
3. Remove viscous fan (1 Figure 2), refer to WIS: AR20.40-P-5660C.
4. Remove clips (6), remove fan shroud (3).
Note:
Models 163.154/172: Remove two 2 screws at bottom of fan shroud.
5. Remove engine belt (2) refer to WIS: AR13.22-P-1202B (special tool: external torx set W001 589 76 09 00).
Note:
Replace engine belt only if belt is damaged due to a deteriorated harmonic balancer pulley. Replacement of belt due to normal wear may not be claimed under this campaign.
6. Remove harmonic damper pulley bolt (4):
^ Position harmonic damper pulley at 40° ATDC.
^ Counter hold crankshaft with special tool: counter holder W112 589 0040 00 and extension (refer to WIS: WF58.50-P-0330-02A)
CAUTION!
For vehicles with automatic transmissions:
Do not counter hold crankshaft at ring gear to remove central bolt (4, Figure 2). Counter hold crankshaft only at spokes of the harmonic damper pulley due to high (harmonic balancer pulley) bolt (4) torque.
^ Remove harmonic damper pulley bolt (4).
Note:
Undamaged harmonic damper pulley bolt may be reused.
7. Remove harmonic balancer pulley (5, Figure 2).
Note:
If there is evidence of related damage to the timing case cover and oil pan due to the harmonic balancer pulley grinding against them, refer to subject D for proper evaluation and repair procedures.
8. Installation is in reverse order.
Note:
^ The (fixed) installation position of the harmonic balancer pulley (5) on the crankshaft is specified by the parallel (woodruff type) key installed on the crankshaft (refer to WIS: GF03.30-P-1600-01C).
^ Lubricate the harmonic balancer pulley bolt head (4) contact surface (where bolt head contacts pulley) with clean engine oil.
^ Torque harmonic balancer bolt (4) in two stages:
First torque bolt to: 200 Nm then turn bolt 95°.
C. ENGINES 112 AND 113 WITH ELECTRIC ENGINE FAN
1. Remove front air filter cover or engine cover as necessary.
2. Remove electric fan (1 Figure 3) and fan shroud (3):
^ Model 163: refer to WIS: AR20.40-P-5000GH
^ Models 208: remove clips securing fan to radiator, disconnect fan harness connector, remove fan (1) and shroud (3) as an assembly.
^ Model 170: refer to WIS: AR20.40-P-5000SV.
3. Remove engine belt (2):
^ Model 163 refer to WIS: AR13.22-P-1202BA
^ Models 208, 210, 215, 220 refer to WIS: AR13.22-P-1202BA
^ Model 170.465 refer to WIS: AR13.22-P-1202SV.
^ Special tool: external torx set W001 589 76 09 00
Note:
Replace engine belt only if belt is damaged due to a deteriorated harmonic balancer pulley. Replacement of belt due to normal wear may not be claimed under this campaign.
4. Remove harmonic damper pulley bolt (4):
^ Position harmonic damper pulley at 40° ATDC.
^ Counter hold crankshaft with special tool: counter holder W112 589 0040 00 and extension (refer to WIS: WF58.50-P-0330-02A).
CAUTION!
For vehicles with automatic transmissions:
Do not counter hold crankshaft at ring gear to remove harmonic balancer pulley bolt (4, Figure 3). Counter hold crankshaft only at spokes of the harmonic damper pulley due to high bolt (4) torque.
^ Remove harmonic damper pulley bolt (4)
Note:
Undamaged harmonic balancer pulley bolt may be reused.
5. Remove harmonic balance pulley (5, Figure 3).
Note:
If there is evidence of related damage to the timing case cover and oil pan due to the harmonic balancer pulley grinding against them, refer to subject D for proper evaluation and repair procedures.
6. Installation is in reverse order.
Note:
^ The (fixed) installation position of the harmonic balancer pulley (5) on the crankshaft is specified by the parallel (woodruff type) key installed on the crankshaft (refer to WIS: GF03.30-P-1600-01C).
^ Lubricate the harmonic balancer pulley bolt head (4) contact surface (where bolt head contacts pulley) with clean engine oil.
^ Torque harmonic balancer pulley bolt (4) in two stages:
First torque bolt to: 200 Nm then turn bolt 95°.
D. EVALUATION OF RELATED DAMAGE TO TIMING CASE COVER AND OIL PAN
1. If damage is only visible on the oil pan, check to see if oil is leaking. If oil is leaking between timing case cover and oil plan, replace oil pan only. Use the appropriate WIS instructions.
2. If damage is visible on the timing case cover and the oil pan, compare the damage to Figure 4.
3. If damage is less than what is shown in Figure 4, check to see if oil is leaking. If oil is leaking between timing case cover and oil plan, replace oil pan only. No additional repairs are required.
4. If damage is of equal or greater extent, replace the timing case cover and the oil pan ONLY. Use the appropriate WIS instructions.