Replacing timing chain

AR05.10-P-7601AA

Replacing timing chain

14.2.12



Removing

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground cable

 Do not connect quiescent current retention device otherwise this may cause damage to the control unit.

Model 203

AR54.10-P-0003P

Models 129, 163, 170, 202, 208, 210

AR54.10-P-0003A

Model 209

AR54.10-P-0003Q

Models 211.061/065/070

AR54.10-P-0003T

Model 215, 220

AR54.10-P-0003I

Model 230.474 /475

AR54.10-P-0003R

All models 463 except 463.241/248 with code 979.

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV

Model 463.248 with code 979

AR54.10-P-0003PM



Notes on battery

All models

AH54.10-P-0001-01A

2

Remove spark plugs

 To ensure that the engine can be easily cranked when drawing in the timing chain, and to avoid the timing chain jumping across. Remove only once spark plug of each cylinder.



Replace spark plugs

Model 163

AP15.10-P-1580GH

Models 220, 230.474/ 475

AP15.10-P-1580AB

Models 210, 208, 202

Models 203, 170, 209, 211 with engine 112

Models 209, 211 with engine 113

AP15.10-P-1580A

3

Remove cylinder head covers

Air filter mounted on vehicle

AR01.20-P-5014B

Air filter mounted on engine

AR01.20-P-5014BV

4.1

Remove fan shroud

 Not models 211.061/065/070, 230.475

Models 220, 230.474

AR20.40-P-6800AB

4.2

Remove electric fan

Model 170

AR20.40-P-5000SV

Models 203, 209

AR20.40-P-5000PV

Model 163.174

AR20.40-P-5000GH

5

Position engine to 40° after TDC of first cylinder.

Engine must not be cranked backwards.

The notches of the camshafts must be pointing in the direction of the inner V.

It must be possible to easily insert the two locking plates.

If this is not possible:

Set the basic position of camshafts

AR05.20-P-6020AU

 The copper plates of the timing chain must be aligned with the scribe marks on the camshaft sprockets.

Owing to the unevenly long paths of the timing chain it may be necessary to crank the engine as many as 14 times till the copper plates get aligned with the scribe marks on the camshaft sprockets.

 On vehicles equipped with an air pump, the combination valve must be unbolted before the right locking plate is inserted.

 Installation: Replace combination valve gasket.



*BA09.20-P-1001-01D

 Locating plate

*112589003200

 Locating plate

*112589013200



Timing chain drive - general

Engines 112, 113

GF05.10-P-9611-01C

6

Remove chain tensioner

Models 163.174, 215, 220

Models 170, 202, 203, 208.365/465

Models 209, 210, 211061/065/070

Model 230.474 with engine 113.992

AR05.10-P-7800CA

7

Remove camshaft position sensor

AR15.10-P-2000A

8

Crank engine in direction of rotation until the link for separating the timing chain is easily accessible

 The separation point for the timing chain is one link down from the copper tab (right).

See new timing chain.

9

Remove camshaft bearing bridge on right

Engine 112, 113

AR05.20-P-7103AU

Engine 113.960 with code (479) Cylinder shutoff

AR05.20-P-7103AV

10

Install holding bush (3) onto camshaft on right

 Only insert bolts (4) until they make contact.

 Holding bush

*112589054000

11

Bolt on holding devices (1, 2) for timing chain at right and left cylinder heads

 Retainer

*112589044000

12

Disconnect timing chain

 Cover over timing case recess with a clean cloth. Parts which have dropped into the timing case recess, must be removed.

AR05.10-P-7601-01AV

 To pull out the old timing chain, connect the old chain to the new timing chain.



Install

13

Draw in new timing chain

 Pull in the new timing chain by turning the crankshaft in its standard direction of rotation.

AR05.10-P-7601-04AV

 Assembly links

*602589024000

 Case

*602589009800

14

Remove retaining devices (1, 2) for timing chain at right and left cylinder head

 Retainer

*112589044000

15

Rivet new timing chain

AR05.10-P-7601-02AV

16

Crank engine in direction of rotation

17

Check timing of engine

AR05.10-P-6858V

18

Take off holding bush (3) on right camshaft

 Holding bush

*112589054000

19

Install camshaft bearing bridge on right

Engines 112, 113

AR05.20-P-7103AU

Engine 113.960 with code (479) Cylinder shutoff

AR05.20-P-7103AV

20

Install camshaft position sensor

AR15.10-P-2000A

21

Installing chain tensioner

Models 163.174, 215, 220

Models 170, 202, 203, 208.365/465

Models 209, 210, 211061/065/070

Model 230.474 with engine 113.992

AR05.10-P-7800CA

22.1

Install fan shroud

 Not model 211.061/065/070, 230.475

Models 220, 230.474

AR20.40-P-6800AB

22.2

Install electric fan

Model 170

AR20.40-P-5000SV

Models 203, 209

AR20.40-P-5000PV

Model 163.174

AR20.40-P-5000GH

23

Install cylinder head covers

Air filter located at vehicle side.

AR01.20-P-5014B

Air filter located on engine side.

AR01.20-P-5014BV

24

Install spark plugs



Replace spark plugs

Models 220, 230.474/ 475

AP15.10-P-1580AB

Models 210, 208, 202

Models 170, 203, 209, 211 with engine 112

Models 209, 211 with engine 113

AP15.10-P-1580A

Model 163

AP15.10-P-1580GH

25

Connect ground cable

Model 203

AR54.10-P-0003P

Models 129, 163, 170, 202, 208, 210

AR54.10-P-0003A

Model 209

AR54.10-P-0003Q

Models 211.061/065/070

AR61.20-P-1105T

Model 215, 220

AR54.10-P-0003I

Model 230.474 /475

AR54.10-P-0003R

All models 463 except 463.241/248 with code 979

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV

Model 463.248 with code 979

AR54.10-P-0003PM

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the running engine

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

26

Run engine and inspect for leaks

Number

Designation

Engines
112, 113

BA09.20-P-1001-01D

Bolt, intake manifold to cylinder head

M8

Nm

20