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  #1  
Old 10-10-2022, 06:22 PM
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OM603 Belt Tensioner Removal Challenge

How much torque should I expect to remove the belt tensioner? I’m pulling on it hard with an SK quality hex bit, though only a 18”-ish ratchet. No movement. I’m fairly strong and heavy, I can flex my snap-on ratchet a decent amount. Which tells me I’ve got some issue.

I know there should be threadlocker of some sort on the bolt. But still…

I’ll put the 1/2” drive 12mm hex and a long bar, but that seems like I could get into a lot of “trouble” if I round it out.

How hard should these be? Are they reverse threaded or something?



I’ve changed pulleys many times but not one of these 60x tensioners. Any advice?

Thanks!

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Old 10-10-2022, 07:35 PM
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I did mine several months ago (om 602). It is just a regular thread IIRC. It does go into the inside of the engine where there is oil. Mine was easy to remove because someone had previously installed with no threadlocker and it was leaking oil from the bolt. You could borrow an impact wrench and try that instead. Make sure you are seated all the way down in the hex before you really crank on it (of course).
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Old 10-11-2022, 08:03 AM
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It’s a tight one no doubt but it’s also threaded into the aluminum timing cover so not extremely tight like the front crank bolt. You’ll probably want to use some carefully directed flame to get the bolt heated up then break it loose. I find the ole “blue wrench” very handy a lot of times. Plus, isn’t one of the formulations of thread locker meant to be heated to release?
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Old 10-11-2022, 02:13 PM
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I believe the tensioner bolt torque is 100 Nm or just under 74 ft/lbs. That was for the early OM603 engines. If you have an FSM, verify the torque, but IIRC, it is stout. Also make sure the washer is there, otherwise torque will be difficult to set on reassembly
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Old 10-11-2022, 02:31 PM
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DIY - 1987 300D serpentine belt tensioner replacement
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Old 10-11-2022, 08:22 PM
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Quote:
Originally Posted by ah-kay View Post
I reviewed this. I just needed a longer breaker bar. I didn’t want to force it.

Alas, after a few miles the pulley boltsheared off for some reason, and when I removed the new tensioner, I found the threads were damaged.



I’m having tensioner issues. But I’m going to create a new thread.

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Current Diesels:
1981 240D (73K)
1982 300CD (169k)
1985 190D (169k)
1991 350SD (113k)
1991 350SD (206k)
1991 300D (228k)
1993 300SD (291k)
1993 300D 2.5T (338k)
1996 Dodge Ram CTD (442k)
1996 Dodge Ram CTD (265k)

Past Diesels:
1983 300D (228K)
1985 300D (233K)
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