I just replaced my alternator and noticed that my serpentine belt was slightly cracked. I ordered a replacement from Phil at Mercedes shop. I am having extreme trouble fitting the new belt onto the pulleys. The belt is exactly the same size as my old one. My E320 has the external damper. I have the MB service manual and have followed the instructions by loosening the tension nut and setting the pointer to the untensioned position. Trying to install the belt I am off by about 2" it seems, when I pull hard on the belt I can see the tensioner pulley move/slide towards the crankshaft, but it still is not nearly loose enough to silde on. Am I missing something with the tensioner pulley? Alsi when I tighten or loosen the tensioning nut it really doesn't seem to do anything. Is the tensioning unit bad? Could some someone give me an idea of how to get the belt installed. I am 1 1/2 hrs. away from MB dealer, if I can't get it repaired myself , it's going to be a flatbed ride.

I have been viewing the shop forum discussions and now realize that I have what looks to me like the original wiring harness. I can see slight breakage in the wire insulation just over my oil filter area. The rest of the wiring harness seems a bit stiff as well. Is this harness a MB dealer item only or is available on the aftermarket ? Any idea of part cost ?

Is there a headgasket problem with the 94 E320 models as well ? My car has 121,000 miles and has been dealer serviced. I have owned it for 10 years and would like to keep it for awhile longer.

Thank you in advance for you advise/assistance

If your old belt came off without problems and measures up to same length to the new, then I would say the path you have taken to run the belt is wrong. Re check this, all things being same the new belt will fit.

I agree withe the previous response; check the route of the belt to ensure it is correct. I had a similar problem even after verifying the routing as correct. Problem solved by loosening (sp?) the alternator, or air pump, or power steering pump (don't remember which) installing the belt and tightening the pump. Probably a failed belt tensioner in my case; maybe your's also.
regards.
Mark