102 Belt Tensioner, Water Pump, Chain, Thermostat

13-346 Changes to the V-ribbed belt tensioning device
From December 1984 all 102 engines with automatic

transmission and engines with manual transmission
and air conditioning and automatic climate control
have a revised tensioning device with an additional
shock absorber. The revised design can also be fitted
to vehicles manufactured prior to this.
Layout of shock absorber for V-ribbed belt

tensioning device
28a Shock absorber

1 Tensioning device
P13-2016-13
Scope of work for retroactive installation
1 Remove, install fan shroud (1) and fan (75), bolt

tightening torque (80), 25 Nm.
P20-0006-13
Copyright DaimlerChrysler AG 11.07.2009 CD-Ausgabe G/09/05 . This WIS print-out will not be recorded by Modification services. Page 1
2 Remove, install V-ribbed belt (13-342).
3 Unscrew fixing bolt (25) and remove belt

tensioner (1) and remove tensioning device.
P13-2013-13
The following parts can be used again:

a Idler pulley (2)
a Bolt (4), tightening torque 30 Nm
a Sealing cover (5)
a Distance sleeve
a Connecting rod (17)
a Lever (18)
a Ball socket (23)
a Adjusting nut (24)
a Adjustment pointer (22)
a Distance washer (26)
a Bolt (25)
P13-2014-13
4 Complete revised tensioning device with the

adopted parts. When assembling tensioning device,
fit on lever (18) of the connecting rod (17) to suit the
tensioning element.
P13-2015-13
5 Install revised tensioning device. When doing
this only do up the fixing bolt (25) loosely. Fit ball
socket (23) under the adjusting nut (24). Screw
tensioning nut onto connecting rod (17).
M
Before carrying out the work (steps 6 to 10), check
whether the crankshaft pulley, rigidly connected with
the vibration damper, has already been installed. If
need be proceed with the work from (step 11).
6 Install retining lock (03-500).
P03-2004-13
7 Unscrew bolt (8a). Remove pulley (13) and

vibration damper (11).
P03-0144-15
8 Install new vibration damper (11). Tighten up
hexagon bolt (8) to 300 Nm.
Note
Replace the necked-down bolt (8a)
M18_1.5_75 by the hexagon bolt (8).
9 Fit new pulley (13). Tighten up combination screw

(15) to 20 Nm.
10 Remove holding interlock.
P03-0142-15
11 On vehicles with air conditioning and automatic

climate control fit a shorter
bracket (36).
Tightening torque:
Bolt (37) 20 Nm
Bolts (33b) 8 Nm
12 Fit bracket (33) to oil pan. Use fixing bolts

M6_25 (33a), tightening torque 8 Nm.
P13-2019-13
13 Fit bracket (32) to timing case cover. Use

fixing bolt M8_70 (52), tightening torque
20 Nm.
14 Attach shock absorber (28a) with fixing bolt

M8_50 (30 and 34) to the brackets (29 and 32),
tightening torque 20 Nm.
15 Put on V-ribbed belt, beginning with the idler
pulley (1) in numerical sequence.
1 Idler pulley
2 Crankshaft
3 A/C compressor
5 Alternator
7 Power steering pump
8 Coolant pump
P13-0038-13
16 Tension V-ribbed belt (13-342).
17 Install fan and fan shroud.
18 On 102.962/982 engines with air

conditioning/automatic air conditioning, without
electronic idle control, replace bypass valve (86)
(white) for idle speed stabilisation, by bypass
valve (green).
P07-2066-13
Job flat rates
Oper. no. Text
Basic work Related work

02-0303/01 Renew crankshaft pulley and shock 16 flat rates or 1.3 h 13 flat rates or 1.1 h
absorber for V-ribbed belt tensioning fixture.
02-0304/01
02-0305/01 Install shock absorbers for tensioning fixture. 13 flat rates or 1.1 h 10 flat rates or 0.8 h
02-0306/01
The operation number is to be placed in front of the book/column number of the respective model.
(see flat rate books or standard texts and flat rates microfilm)
The teeth on the inner sleeve (arrow) has been
deleted in order to achieve a high security against
loosening or breakage of the fixing bolt.
Production breakpoint 05/1985
A 1st design
B 2nd design
P13-0044-13
Since June 1985 the 124.02 and 201.02/03 models

have a revised shock absorber. The differences are
the outside diameter of the attachment eye, the length
of the shock absorber housing and the bracket (29),
which is no longer welded to the shock absorber. The
revised shock absorber can also be fitted into
vehicles produced prior to this.
A 1st design
B 2nd design
P13-2017-13
Repair note
The bracket (29) is to be attached to the shock
absorber with the hexagon socket screw M6_25 (30)
in accordance with the table.
P13-2033-13
Engine Manual Automatic up to from Bracket on shock absorber

transm. transm. engine engine bore
end No. end No.
A B
102.922/924 universal universal universal universal X
102.962/963
102.982
102.962 H X 048640 X
X 048641 X
X 023924 X
X 023925 X
102.985 X 002293 X
X 002294 X
X 019688 X
X 019689 X
Parts Part no.

All Shock absorber 102 200 07 14
engines (28a)
Bracket (29) 102 202 21 40
Hexagon socket 007984 008063
screw M8_14 (30)
P13-2019-13
Production breakpoint
Model Chassis or vehicle identification end No.
A F
124.020/021 064785 -
124.023 062473 -
201.023 227969 126517
201.024 227434 124444
The fixing bolt for the belt tensioning device

M12_115 has a longer thread (100 mm, previously
30 mm).
Production breakpoint 04/1986
Since June 1986 V-ribbed belts with revised material

(as on engine 601, 602 and 603) have been fitted.
Since October 1986 an adhesive plate with
revised adjustment scale for tensioning the
V-ribbed belt has been progressively introduced
on the tensioning device.
A Adhesive plate 1st design

B Adhesive plate 2nd design
P13-2097-13
Since January 1987 a revised tensioning fixture has

been fitted (102.985 engine since July 1986). This
tensioning fixture has an additional pressed bracket
(47), a collar screw (25), previously hexagon bolt, and
a reinforced bracket for the tensioning device.
25 Collar screw
47 Pressed bracket
P13-2098-13
This reinforced bracket is to be identified by the cast-

in Part No. 102 202 28 40.
Reinforced bracket
P13-2099-13
Changes to the tension lever
1st design
Two single row ball bearings (6 and 7),
wide rubber bearing (13),
hexagon bolt (25) 12_115 mm,
tension lever (18) and distance sleeve (21),
tie rod (17), attached to the tension lever (18) with
bolt (19) and secured with clips (20).
P13-0045-15
2nd design
A double row angular ball bearing (40),
narrower rubber bearing (13),
collar screw (25) M12_110 mm,
one piece tension lever (18),
tie rod (17), attached to the tension lever (18)
with sheet metal locking device (46).
P13-0046-15
Fit revised tensioning device retroactively
1 Remove V-ribbed belt (13-342).
2 Remove lower engine compartment panelling.
3 Slacken bolt (34) and swing shock absorber (28)

downwards. Completely screw out bolt (25) and
remove tensioning fixture (1).
P13-2018-13
4 Remove pulley for power steering pump.
5 Undo nut from bolt (39) behind power steering

pump/A/C compressor support.
6 Unscrew bolts (48 and 48a).
P13-2024-13
7 Install revised tensioning device with pressed

bracket (47). Grease collar screw (25) M12_110 on
the thread and the support area and screw in.
Assemble adjusting nut.
8 Attach pressed bracket (47) with longer bolts.

Bolt (39) M8_95
(48) M8_45
(48a) M8_55
Tighten up the nut of bolt (39) and bolts (48 and 48a),
9 Install power steering pump pulley, tightening

torque 30 Nm.
10 Attach bracket (29) and shock absorber (28) to

tensioning fixture. Tighten up bolts (31 and 34),
11 Fit V-ribbed belt (13-342).
12 Install engine compartment panelling.
13 Push adjustment pointer (22) to the left until the
tip is directly over the scale marking (A). Then turn
the adjusting nut (24) to the right until the tip of the
adjustment pointer is directly over the scale marking
(E). Tighten up collar screw (25), tightening torque 80
Nm.
P13-2025-13
Standard text and flat rates
Removing, installing, checking, V-belt tensioning device, and renewing as necessary
13-0085 Basic work: 15 flat rates or 1.3 hours

13-0090 Related work: 12 flat rates or 1.0 hours
The operation number is to be put in front of the book/column number of the respective model.
Parts Engine Part no.

Tensioning fixture (supply schedule) 102.922/924/962/963/982/985 102 200 66 70
Since January 1987 the collar screw (25)

M12_110 has been changed to a hexagon bolt with
washer M12_115.
P13-0047-13
Revised fitting position of the shock absorber
Since November 1987 the shock absorber has been

fitted overhead (previously underneath).
Bottom installation position (1st design).
P13-2018-13
Top installation position (2nd design)
P13-2100-13
The following parts have been changed:
a Shock absorbers;
Note
In the event of repair do not confuse the shock
absorbers for the upper and lower fitting position.
The shock absorber Part No. 102 200 12 14
(overhead) can be fitted for the shock absorber Part
No. 102 200 08 14 (underneath). On engines prior to
November 1987 the overhead shock absorber cannot
be fitted retroactively.
a Tensioning device with additional cast eye (B) for
fixing the shock absorber.
A 1st design
B 2nd design
P13-2103-13
a Coolant pump (see group 20)

a Vibration damper (see group 03)
a Pressed bracket (B) for attaching alternator with
M8 welded nut for attaching the shock absorber
(arrow).
A 1st design
B 2nd design
P15-0407-13
Since January 1988 the bracket (B) for supporting the

tensioning device has been fitted with a welded-on
eye (arrow).
P13-2101-13
05-310 Removing and installing chain tensioner
Preceding work: Operation No. of operation texts and operation values or standard
Poly-V-belt removed (13-342). texts and flat rates
05-7800
P05-0086-57
Bolt (49) slacken (step 1)

Bolt (51) unscrew (step 2).
Alternator swing outward (step 2).
Locknut (40) unscrew.
M
Locknut (40) is pressurized (step 3).
Seal (41) replace (step 8).
Compression spring (39) take off, insert (steps 3 and 8).
Chain tensioner casing (36) with setbolt (37) unscrew (step 4).
Setbolt (37) with locking spring (38) press out of chain tensioning casing in the
direction of pressure. Check individual parts
for wear (step 5).
Chain tensioner casing (36) screw into cylinder crankcase, 15 Nm
(step 6).
Setbolt (37) with locking spring (38) push in (step 7).
Locknut (40) with compression spring (39)
and new sealing ring (41) screw in, 70 Nm (step 8).
Alternator mount (step 9).
When engine is running check for leakage.
Special tools
001 589 72 21 00 001 589 66 21 00
Commercially available tool
Stud driver insert e. g. Hazet,

17 mm, 1/2" square D-42804 Remscheid
Order no. 985/17
Note
The housing (36) of valveless, hydraulic lock chain
tensioner is screwed in the crank case (1). The
application force required to tension the chain is
comprised of the force from compression spring (39)
and oil pressure in the chain tensioner, depending on
engine oil pressure.
P05-0070-13
In the event of sudden load the oil feed bore with 1.1
mm Q (a) and an orifice bore (b) in the setbolt of 1.2
mm Q prevents the oil escaping rapidly and thus has
a damping effect. An embossing is provided in the
chain tensioner casing (36) and a locking spring (38)
on the setbolt.
P05-2052-13
36 Chain tensioner casing

37 Setbolt
38 Locking spring
39 Compression spring
40 Locknut
41 Sealing ring
The locking spring (38) has been modified in order to

improve the function of the chain tensioner.
Changes:
a Ends free from burrs
a Smaller twist
(dimension "a" = 0.1 mm, was 0.5 mm)
a Improved material
a Dimension "b" = 3.5 mm, was 4.0 mm.
Production breakpoint: 12/1985
P05-0170-13
Removing and installing

-------------------------------
1 Slacken lower bolt (49) for alternator fixing.
2 Unscrew upper bolt (51), swing alternator

outwards (arrow).
P15-2038-13
3 Unscrew locknut (40) and sealing ring (41) and
remove compression spring (39).
M
Locknut (40) is pressurized by the compression spring.
P05-2043-13
4 Unscrew chain tensioner case (36) from the

cylinder crankcase with the stud driver insert.
P05-2067-13
5 The chain tensioner must be stripped down

before assembly. To do this press the setbolt (37) and
locking spring (38) out of chain tensioner casing (36)
in the direction of the arrow. Clean parts and check
for wear.
P05-2080-13
6 Screw chain tensioner casing (36) onto

crankcase, tightening torque 15 Nm.
P05-2071-13
7 Push setbolt (37) and locking spring (38) into the
assembled chain tensioner casing.
P05-2088-13
8 Mount compression spring (39) and locknut (40)

with new sealing ring (41), tightening torque 70 Nm.
P05-2043-13
9 Mount alternator, tightening torque of the

bolts (49 and 51), 25 Nm.
10 Install in the reverse order.
11 Check for leaks when engine is running.
P15-2038-13A
20-110 Removing and installing coolant thermostat
Drain - fill in coolant (20-010). texts and flat rates
20-2460
P20-0034-35
Cap (31) unscrew with connected coolant hose, screw on,

tightening torque for light alloy cap 10 Nm, plastic
cap 8 Nm.
O-ring (32) renew.
Coolant thermostat (30) remove and install.
Note
Install the coolant thermostat so that the ball valve is
at the highest point.
Cooling system check for leaks (20-017).
Special tools
124 589 15 21 00 000 589 67 21 00
05-320 Renewing timing chain
Air cleaner removed (09-400 and 09-410). texts and flat rates
Cylinder head cover removed (01-406). 05-7601
P05-0085-57
Spark plugs (15) remove, install (15-530).

Chain tensioner (36 to 41) remove and install (05-310).
Chain bolt grind off (step 3).
New timing chain with old timing chain (21) connect, pull in (steps 4 to 7).
Exterior bracket press on with riveting tool 000 589 58 43 00
and rivet set 103 589 01 63 00 (for single roller
chain) (steps 8 to 10).
Riveting tool remove, convert (step 11).
Connector link bolt rivet individually (steps 12 and 13).
Special tools
102 589 01 09 00 000 589 58 43 00 103 589 01 63 00
Note
There is an open timing chain with connector link for
repairs. The sprockets are to be checked for scores
and pitting as well as the chain tensioner for perfect
function before installing a new timing chain.
Improved timing chains have been fitted since

November 1985.
Changes:
Sleeves (2) with recesses (notches, arrow and A).
Hence improved oil supply to bolts (3) and sleeves (2).
P05-0165-13
A double roller timing chain has been installed since

January 1988.
Double roller timing chain, production breakpoint: January 1988
Model Engine Engine end number Engine end number

Manual transmission Automatic transmission
124.020 102.922 057135 022831
124.080
124.021 E 102.963 006835 000357
124.023 102.982 091912 088447
124.043
124.083
201.023 102.924 042151 010535
201.024 102.962 166152 084537
201.028 102.985 022013 067143
The former connector link with locking devices (A)

has been deleted. Only the connector link (B) is still
supplied for riveting.
A Former connecting link with locking devices

B Modified connecting link - can be riveted
P05-2057-13
Renewal
-------------------------------
1 Remove, install spark plugs (15-530).
2 Remove, install chain tensioner (05-310).
3 Cover the open part of the chain casing with a

rag, grind off both chain bolts (arrows) at a double link
in the timing chain.
P05-2050-13
4 Attach new timing chain and the connector link

onto the old timing chain. To do this press out ground
off double link.
5 Put the new timing chain connected with the old
timing chain onto the camshaft timing gear.
Rotate crankshaft.
M
The timing chain must remain in mesh whilst rotating
the camshaft timing gear.
P05-2074-13
6 Pull out the released end of the old timing chain

evenly, to correspond with drawing on the new timing
chain.
M
The timing chain must remain in mesh whilst turning
the camshaft timing gear and crankshaft gear.
7 Secure the ends of the chain to the camshaft

timing gear with wire. Detach old timing chain and
connect the ends of the new timing chain with the
repair connector link.
Note
Connector link must be inserted from behind.
P05-2075-13
8 Depending on the timing chain version (sim-

ple or double roller chain), insert in the case of
simple roller chain the rivet set 103 589 01 63 00
for the basic tool 000 589 58 43 00.
9 Put loosely attached exterior bracket of the

connector link in the press tool (arrow).
The exterior bracket is held magnetically.
P05-2053-13
10 Fit rivet tool onto the link and press on bracket up
to the stop.
Note
Put on clip so that both rivet pins engage.
P05-2081-13
11 Remove rivet tool and turn punch (02) so that the

notch (arrow) points forward.
P05-2056-13
12 Position rivet tool exactly over the center

bolt. Rivet bolts of the connector links
individually, tightening up spindle to approx.
30 - 35 Nm (reference value).
P05-2072-13
13 Check riveting (arrows), re-rivet if required.
14 Fit chain tensioner (05-310).
P05-2051-13
15 Turn crankshaft and check adjustment markings
at engine TDC position.
Note
If the adjustment markings do not align, the valve
timings of the camshaft must be checked
(05-215).
16 Assembly continues in the reverse sequence.
P05-2008-13
20-210 Removing and installing coolant pump
Draining - filling in coolant (20-010). texts and flat rates
Removing and installing V-belt (13-342). 20-1270
P20-0031-55 A
Belt pulley (72) unscrew, screw on, tightening torque of hex. socket
bolt 10 Nm, Torx socket bolt 15 Nm (step 3).
Cable connector (68a) detach from solenoid body, plug in (step 4).
Solenoid body unscrew, screw on, pay attention to installed
position, tightening torque 10 Nm reference value
(step 4).
Coolant hoses (56, 57 and 58) detach, attach (step 5).
Bolt (50) for shock absorber (28), unscrew, screw on,
tightening torque 25 Nm (step 6).
Bolts (51) unscerw, screw on. Place alternator with connected
cable to the side (step 7).
Bracket (156) detach, attach by removing bolts (49, 3 ea.),
screwing on, tightening torque 25 Nm.
Coolant pump (1) unscrew, screw on, pay attention to bolt length,
tightening torque 10 Nm. Clean sealing surfaces
(step 10).
Note
Only use paper gasket 102 201 00 80 (2) if the
timing case cover is sealed with liquid sealant.
Otherwise seal coolant pump with sealant
002 589 00 20 10.
Special tools
001 589 72 21 00 124 589 15 21 00
7 mm wrench socket on flexible shaft eg. Hazet, D-42853 Remscheid

for hose clips with worm drive Order no. 426-7
Note
The pump chamber for the impeller of the coolant
pump is located in the timing case cover (arrow).
P20-2054-13
Components
The bearing (2) of the coolant pump shaft and the
cassette-type seal (6) are press-fitted into the coolant
pump housing.
1 Coolant pump housing
2 Coolant pump bearing
6 Cassette-type mechanical seal
15 Impeller
68 Solenoid body
68b Carrier
72 Belt pulley
73 Flange
74 Fastening bolts
75 Fan
76 Angular-contact ball bearing
77 Armature
78 Tensioning pulley
79 Pulley
80 Fastening bolt
P20-0027-15
Removal and installation

-------------------------------
1 Drain coolant, fill in (20-010).
2 Remove and install V-belt (13-342).
3 Unscrew belt pulley for coolant pump.
Note
Pay attention to bolt versions and tightening torques.
Hex. socket bolts 10 Nm

Torx socket bolts (as of 9/85) 15 Nm P20-2052-13
4 Disconnect cable connector (68a), plug in,

unscrew solenoid body (68), screw on (arrows).
P20-2051-13
5 Detach coolant hoses (56 and 57) as well as
bypass line (58), connect.
P20-2154-13
6 Unscrew bolt (50) for shock absorber of belt

tensioning device, screw on, tightening torque
25 Nm.
7 Unscrew bolts (51) and place alternator to the

side.
Tightening torque 45 Nm.
8 Unscrew bracket (156), screw on, tightening

torque 25 Nm. For this step, remove bolts
(49, 3 ea.), screw on, tightening torque 25 Nm.
P20-2049-13 A
9 Detach coolant pump, attach. For this step,
remove bolts (21), screw in, tightening torque
10 Nm. Pay attention to bolt length.
10 Clean sealing surfaces.
Note
A paper gasket Part No. 102 201 00 80 is
supplied in the parts sector as a seal of the
coolant pump at the timing case cover. This
gasket may only be fitted if it is assured that the
timing case cover is sealed only with liquid
sealant. Otherwise use sealant
002 589 00 20 10. P20-2048-13
11 Check cooling system for leaks (20-017).
20-115 Removing and installing coolant thermostat housing
Drain - fill in coolant (20-010). texts and flat rates
20-2710
Vent line (65) disconnect, connect (step 2).

Lifting lug (22) unscrew, screw on. Tightening torque 25 Nm (step 3).
Hose clip (38, 38a) at top of bypass hose, slacken, tighten (step 4).
Coolant thermostat housing (29) unscrew, screw on. Tightening torque 25 Nm (step 5).
Gasket (36) renew (step 6).
Special tools
124 589 15 21 00 001 589 72 21 00
7 mm socket wrench hexagon on flexible shaft eg. Hazet, D-42853 Remscheid

for hose clips with worm drive Order no. 426-7
Note
Since January 1985, Model 201 has been fitted with a
plastic coolant thermostat housing.
The gasket to the cylinder head is manufactured from

rubberized cork.
The vent line is pushed on with a hose clip; previously

with hollow screw (arrow).
Since May 1987, a light alloy thermostat housing has

been installed.
The previous plastic cover continues to be fitted.
Since May 1987, the light alloy base section of the

coolant thermostat housing has again been installed.
The plastic housing cover is retained.
The gasket to the cylinder head is made of paper.
A 1st version
B 2nd version
Removal and installation
-------------------------------
1 Draining - filling in coolant (20-010).
2 Detach vent line (65) at the cap of the coolant

thermostat housing, connect (arrow).
3 Unscrew lifting lug (22, only on engines with

hydraulic oil pump), screw on.
Tightening torque 25 Nm.
4 Slacken hose clip (arrow) at bypass hose, tighten.
5 Unscrew coolant thermostat housing (29), screw

on. Tightening torque 25 Nm.
6 Clean sealing surfaces, renew gasket.
7 Check cooling system for leaks (20-017).

102 Belt Tensioner, Water Pump, Chain, Thermostat

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13-346 Changes to the V-ribbed belt tensioning device

From December 1984 all 102 engines with automatic

Layout of shock absorber for V-ribbed belt

28a Shock absorber

Scope of work for retroactive installation

1 Remove, install fan shroud (1) and fan (75), bolt

3 Unscrew fixing bolt (25) and remove belt

The following parts can be used again:

4 Complete revised tensioning device with the

6 Install retining lock (03-500).

7 Unscrew bolt (8a). Remove pulley (13) and

9 Fit new pulley (13). Tighten up combination screw

10 Remove holding interlock.

11 On vehicles with air conditioning and automatic

12 Fit bracket (33) to oil pan. Use fixing bolts

13 Fit bracket (32) to timing case cover. Use

14 Attach shock absorber (28a) with fixing bolt

16 Tension V-ribbed belt (13-342).

17 Install fan and fan shroud.

18 On 102.962/982 engines with air

Job flat rates

Oper. no. Text

Basic work Related work

Since June 1985 the 124.02 and 201.02/03 models

Engine Manual Automatic up to from Bracket on shock absorber

Parts Part no.

The fixing bolt for the belt tensioning device

Since June 1986 V-ribbed belts with revised material

A Adhesive plate 1st design

Since January 1987 a revised tensioning fixture has

This reinforced bracket is to be identified by the cast-

Fit revised tensioning device retroactively

1 Remove V-ribbed belt (13-342).

2 Remove lower engine compartment panelling.

3 Slacken bolt (34) and swing shock absorber (28)

5 Undo nut from bolt (39) behind power steering

6 Unscrew bolts (48 and 48a).

7 Install revised tensioning device with pressed

8 Attach pressed bracket (47) with longer bolts.

9 Install power steering pump pulley, tightening

10 Attach bracket (29) and shock absorber (28) to

11 Fit V-ribbed belt (13-342).

12 Install engine compartment panelling.

Standard text and flat rates

Removing, installing, checking, V-belt tensioning device, and renewing as necessary

13-0085 Basic work: 15 flat rates or 1.3 hours

Parts Engine Part no.

Since January 1987 the collar screw (25)

Since November 1987 the shock absorber has been

Bottom installation position (1st design).

Top installation position (2nd design)

The following parts have been changed:

a Coolant pump (see group 20)

Since January 1988 the bracket (B) for supporting the

Bolt (49) slacken (step 1)

001 589 72 21 00 001 589 66 21 00

Commercially available tool

Stud driver insert e. g. Hazet,

36 Chain tensioner casing