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Well, Pimpernell, you had the noise down. Replacing the belt tensioner shock seems to have taken care of my noise issue. I'm really amazed, as the noise sure sounded like it was coming from below the intake manifold.
I tried your method for removal of the lower bolt (i.e. pliers, screw driver, and a lot of patience. Frankly I don't know how you managed to get that damned bolt out! I fooled with mine for several hours (after looking at the manual and deciding I didn't want to buy the special tool that I would probably use only once!) I couldn't get a Dremel onto the bolt head, so filed it down to ~ 4mm... still couldn't get it out.
After about 4 hours, I decided to push the bolt out as far as it would go, then took a sabre style hacksaw to the bolt. This shortened it ~ 7mm, but it still has enough about 8mm of thread, and attached the shock to the engine just fine.
Noise gone!
This should be such a simple part replacement... why MB engineers decided to make it so difficult baffles me. To have to remove the fan shroud, fan, fan clutch, and belt (as described in the Star manual) just to get a bolt out (rather than making the bolt shorter, or putting an access hole in the belt pulley) sure seems a bit like poor planning.
Anyway, thanks all for your guidance!
-l-
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'84 300d turbodiesel (83K miles)
'96 300d (226K miles)
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other fine diesels...
'99 Polaris diesel (Fuji Heavy Industries single)
'01 Diesel Trail gator (Yanmar triple)
'95 John Deere 970 (Yanmar quad)
'11 BMW 335d
'12 VW Jetta TDI
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'00 BMW K1200LT
'02 BMW R1150RS
'15 BMW R1200GSA
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