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  #1  
Old 11-11-2010, 02:58 PM
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Tensioner pulley out of alignment '87 300D turbo

I need some help, my tensioner pulley it out of alignment and slightly askew on my 1987 300D Turbo (i think the x603). I have already replaced the pulley and arm once thinking that would fix it but after the replacement it didn't look too much better. It keeps eating belts and ruining the bearings in the alternator which cause the belt to fail. I don't know an easy solution with out trying to replace the timing chain cover thinking that it is either cracked (not leaking oil) or the bolt hole is cross threaded or something. I don't know what to do, any ideas or help? Take a look at the pictures, thanks in advance.

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Tensioner pulley out of alignment '87 300D turbo-img_1057.jpg   Tensioner pulley out of alignment '87 300D turbo-img_1058.jpg   Tensioner pulley out of alignment '87 300D turbo-img_1062.jpg   Tensioner pulley out of alignment '87 300D turbo-img_1063.jpg  
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  #2  
Old 11-11-2010, 03:22 PM
LarryBible
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I have never messed with the tensioner on this particular engine, only it's gas cousins, so maybe I can think outside the box, hopefully to give you a fresh perspective.

My first curiosity is whether or not you have the correct tensioner. Do you have the original in a scrap pile somewhere so that you can compare? Do you have the right pulley on the tensioner? Have you used a straight edge to verify misalignment? Are you sure that it is the tensioner pulley and not one of the other pulleys that is the culprit? The straight edge could confirm this.

You don't have a bracket in the wrong place spacing a pulley out or something do you?

I'm sorry I can't help further. I would encourage you to use a straight edge and don't take anything for granted.

When I was a kid helping my Dad in his shop and got stumped I would go begging for help from my Dad. One of his common responses was, "whatever you have NOT checked is probably the trouble.

Best of luck and keep us posted.
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  #3  
Old 11-11-2010, 03:25 PM
LarryBible
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It's just like me to reply BEFORE looking at the pictures. The one pulley that looks like the offender doesn't look to be misaligned as it does "loose." It appears to be at an angle. This is the sort of thing that's kind of hard to make much out of without being there.

The most important trait of a good troubleshooter is to be vindictive. Approach the problem as an adversary who's A$$ you are intent on kicking. Don't give up.

Good luck,
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  #4  
Old 11-11-2010, 05:27 PM
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new arm??

your arm looks old..did you buy a used one?.i have one thats good used i changed when swapping engine you can have for postage.
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  #5  
Old 11-11-2010, 09:44 PM
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The tensioner arm where it mounts to the chain-cover casting has a bearing, which in your car appears to be very worn-out.
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  #6  
Old 11-11-2010, 10:52 PM
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Quote:
Originally Posted by patr1707 View Post
I need some help, my tensioner pulley it out of alignment and slightly askew on my 1987 300D Turbo (i think the x603). I have already replaced the pulley and arm once thinking that would fix it but after the replacement it didn't look too much better. It keeps eating belts and ruining the bearings in the alternator which cause the belt to fail. I don't know an easy solution with out trying to replace the timing chain cover thinking that it is either cracked (not leaking oil) or the bolt hole is cross threaded or something. I don't know what to do, any ideas or help? Take a look at the pictures, thanks in advance.
Was the arm (tensioner) and pullet replaced with new or known good parts? Some original factory setups use a large thick washer between the tensioner and the timing cover, if you're not certain whether your engine did, you might find out by using the EPC and instead of a generic model picked from the list put your VIN into the EPC and that usually is more specific as for as particular configurations and cut-offs to production changes.

Probably the most straight forward way of determining if the timing cover has been cross threaded is to get hold of a 4-5" long M18 X 1.5 threaded rod
or a bolt and cut the head off. Then you can thread it into the place of the tensioner's bolt. With that bolt it place it should be pretty easy to see if it's not square to the timing chain chase cover. If it's not easily apparent you can use a straight edge and a square off the crank pulley for a reference.

If the timing cover threads are cross threaded you don't have too many good options, R&R of the cover or possibly a thread fix of some sort.
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  #7  
Old 11-11-2010, 11:55 PM
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ok, here's what I'd do...
step one... spray a good degreaser in there, and let it soak, then brush it well.
step two... rinse well, get all the pulley's and lines CLEAN
three. remove the shroud and fan assembly
four. get the tensioner assembly removed and inspect it.
five. replace what's broken. if the pivot bearing is sound, and the bolt and washer are present and good... the only thing left is the timing cover. if this recently happened, it's likely just a bad bearing in the pivot. if it's been like this since you got the car from a recent purchase, well then you could be fixing previous repairs...

and, while you are in there, you should look at your vacuum pump. does it have bolts holding the outer cover on or is it just pinched together? these pumps are known to fail in odd ways, and kill the motor.
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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  #8  
Old 11-15-2010, 12:22 PM
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Thanks for all the ideas guys! Here's an update:

I took a second look at it and it appears that there is no washer in between the tensioner and the timing chain cover. As of now when there is no tension on it the tensioner and the pully can "wiggle" back a forth about 3/4 inch. The only thing keeping the pully from hitting the fan blades is that the other end where the dampener is attached is hitting the timing chain cover. So I take it that the bearing inside the tensioner is shot and I need to replace it. I won't be able to do that until next weekend or over Thanksgiving as I am on the road for work, so for now I am praying that nothing bad happens to it. I have already replaced the belt once in the past month and this one seems to be holding ok.

When I put the one that is currently in, it was purchased new and I compared side by side and they looked the same. I still have the old one and the bearing or bushing on that one doesn't seem to be too bad and when I replaced it there was not a washer or spacer on that one either so I guess who ever did the job the last time fail to put it in.

Where is the best place to get the parts to fix it and what else should I replace while I'm in there with the radiator out?

vstech: You said there is a vacuum pump down there? I though there was one under the air filter box? I am slightly confused, is there one on the front of the engine?

Thanks for all the help!

-P
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  #9  
Old 11-15-2010, 12:52 PM
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Are you using the proper size (lengthwise) of belt.

I once went through 3 alternators (bearing issues) and one bent tensioner pulley because I was using the wrong belt.

I installed a belt for the 350sdl engine. I should have put on the belt for a 300sdl. It was one inch shorter and enough to damage the bearings.
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  #10  
Old 11-15-2010, 12:53 PM
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so... you are DRIVING this car this way?
ya know, the timing cover is several hundred dollars of repairs IF you can change it without damaging the head gasket...
I would NOT put another moment of idle time on that motor until I got that tensioner out of there...
ASAP!

the vacuum pump is to the right of the belt tensioner facing the motor it has two lines on top, a tiny 1/8" one and a large 17mm nut attached one. look at the flat face of the pump, it should have 5 or 6 allen screws holding the face onto the pump. if it's flat with just some bent tabs on it, you have the original pump on there, and it needs to be replaced before it fails and takes out your motor!
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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  #11  
Old 11-15-2010, 01:36 PM
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I am kind of stuck driving the car yes, I am in NYC for work and home is Massachusetts. I have no way to work on it here unless I go to a dealer or mechanics shop. I am kind of broke and like to do the work on it myself because I know how to do most of it. I guess I could suck it up and bring it some where down here in Newark.

Also, does anyone know the size of the allen key that the tension bolt is that bolts to the timing chain cover?

I have looked in the parts shop but cannot find the vacuum pump, where can I get one?

Does anyone know the correct length that the belt should be? I just go to the auto parts store and they look it up for me, 1987 300D Turbo 3L SOHC x603.
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  #12  
Old 11-15-2010, 02:15 PM
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Quote:
Originally Posted by patr1707 View Post
I am kind of stuck driving the car yes, I am in NYC for work and home is Massachusetts. I have no way to work on it here unless I go to a dealer or mechanics shop. I am kind of broke and like to do the work on it myself because I know how to do most of it. I guess I could suck it up and bring it some where down here in Newark.

Also, does anyone know the size of the allen key that the tension bolt is that bolts to the timing chain cover?

I have looked in the parts shop but cannot find the vacuum pump, where can I get one?

Does anyone know the correct length that the belt should be? I just go to the auto parts store and they look it up for me, 1987 300D Turbo 3L SOHC x603.
The tensioner Allen head is 12 mm, you can get a set 12,14,17 mm of 1/2" drive tools at Auto Zone for about $10.

The correct belt length for an OM 603.96X in an 87 300D with AC is 2145 mm.

Here you go!
http://catalog.peachparts.com/ShopByVehicle.epc?q=&yearid=1987%40%401987&makeid=63%40%40MERCEDES+BENZ%40%40X&modelid=6189%3AED%7C10000096%3AMBC%7C1626%40%40300D&keyword=vacuum+pump&subcatid=P:240732@@Diesel%20Vacuum%20Pump&mode=PA

http://www.allpartsexpress.com/ShopByVehicle.epc?q=1987-MERCEDES--BENZ-190dt--/l5_--.5l_diesel_turbo-Engine&yearid=1987&makeid=MERCEDES+BENZ%40%40MERCEDES+BENZ%40%40X&engineid=1192575%40%40190DT+%2FL5%5F2%2E5L%5FDIESEL%5FTurbo%40%40190DT&catid=Engine&subcatid=Vacuum%20Pump&mode=PA

If you elect to go used I have a good used updated style pump with about 155K on it available for $165 shipped USPS Priority Mail, you can have it in your hands in a day or two, good luck!
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  #13  
Old 11-15-2010, 08:51 PM
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As I am over 300 miles from home and have to drive back next weekend, and with all of you help I have decided to bite the bullet and bring her to a mechanic to get it fixed, I got an estimate of 600$ for everything. I wish I could do it my self but am really afraid that I won't be able to make it home. Thanks for all the help!
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  #14  
Old 11-15-2010, 10:33 PM
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... wow.
for 600.00, I'd pull into an autozone and use their parking lot to pull and replace the pivot.
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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  #15  
Old 11-18-2010, 08:53 PM
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UPDATE: I hate to tell you this but I opted to do the job myself. Which means I drove the 350 miles home with the tensioner pulley millimeters from the fan. I made it and the car will sit till I get the parts that I just ordered. Doing it myself will save me about 400$.

One question, I think the problem may be that there is not washer or spacer between the pivot arm and the timing chain cover causing it to go out of alignment like that, does anyone know where I can get that spacer or have any specs on what it is?

Thanks

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