Illustrated report on fixing the tension roller of the Mercedes OM 601-603 belt

I suppose that a number of people have sooner or later faced the defect of the tension roller in general and the rocker arm bearing failure in particular. Personally I had a situation when I needed to restore the normal operation of the car urgently. It was a Friday night when I found out that the tension roller was at a crooked angle, and next Saturday morning I was going to drive to Brest, and you need to realize that the distance is rather long, who knows what may happen… So I solved this problem by installing two 6004 2rs inline ball bearings instead of the single wider one. I cost me as low as 2$ to solve the question. Later I found out that the normal ball-bearing price in a local store starts at 15$ and even higher prices. When I went to an ordinary market I was astonished: the cheapest price was 30$. So I decided not to by the news ones. At this very moment I have driven more than 40,000 km and everything works fine. Last week I made the same operation to a friend of mine and made some photos, so I decided to make this illustrated report afterwards.

Now let us go step by step.

1. Knock out the pin and remove the lock ring.

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2. Remove the ball bearing itself.

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3. Wear-out of true can be seep with the naked eye.

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4. The size of a standard ball bearing is 20*42*29 mm while the 6004 rs2 ball bearing is 20*42*12 mm. So we need to create a ring with the size of 20*30*5 mm. If you have no turner among your friends I suggest you use the old bearing cage and a slitting cutter. Let the jointing edge be your orienting point.

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5. Grip in a vice, but really hard, and cut it off, carefully fit afterwards.

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6. Now we have got the ring ready.

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7. Usually new ball bearings lack lubricant. Open the dust cap and add as much lubricant as it fits there.

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8. Knock the first ball bearing.

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9. Install the intermediate ring we have created before. Add some more lubricant for it not to move around freely after we add the second ball bearing.

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10. Knock the second ball bearing.

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11. Knock the pin. Install the lock ring. The roller is ready!

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I wish good luck to everyone. Do not judge me strict – this is my first photo-report.

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