Engine - Accessory Drive Belt Noise
Date: November 17, 2008Order No.: P-B-13.20/03a
Supersedes: P-B-13.20/03 dated May 23, 2008
Group: 13
Revision History
SUBJECT:
Model 203.040/740
Noise from the Belt Drive
If you receive customer reports in the above model vehicles of noises from the belt drive, the cause could be the freewheel of the alternator pulley is seized or has excessive resistance. Follow the procedure below for corrective actions.
1. Remove the poly-V-belt.
2. Pry the plastic cover off the end of the alternator pulley (Figure 1, G2). Insert socket wrench tool (W602 589 00 10 00) to hold the shaft from turning. Turn the pulley clockwise by hand and it should lock. Turn the pulley counterclockwise, it should freewheel.
3. If the pulley did not freewheel, it needs to be replaced. It is not necessary to replace the alternator.
4. Use a 17 mm wrench on the end of the socket wrench tool and hold it stationary (allow it to contact the frame/sub frame). Insert socket through the center of the socket wrench tool and into the end of the alternator shaft. For Bosch alternators, use M10 socket W601 589 00 10 00 and for Valeo alternators use a long Torx 50 socket available commercially. Turn the socket clockwise to remove the pulley (Figure 2). Remove spacer on Valeo alternator (Figure 3).
5. Confirm correct length of pulley, long pulley for Valeo and shorter pulley for Bosch and Valeo, refer to EPC (Figure 4). Install new pulley and tighten with the socket counterclockwise to 80 nm. Use a torque wrench that functions in both directions. Install new plastic cover on end of pulley. It is important to follow loosening and tightening instructions as described.
NOTE: A seized alternator pulley freewheel will cause the belt tensioner to oscillate back and forth when the engine is running. It can also cause the failure of the AC compressor pulley, refer to DTB P-B-83.55/87b (or latest version).
Special Tools
Parts Information
NOTE: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on May 23, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Belt pulley for alternator, check (15-0000)
Belt pulley for alternator, replace (V-belt removed) (15-5708)
Poly V belt - single belt drive, replace (13-1202)