Crankshaft Gear/Sprocket: Service and Repair

REMOVAL
1. Raise hood to vertical position.

Setting TDC:

2. Position piston of No. 1 cylinder to TDC.
3. Remove tensioning rail.
4. Cover over oil sump with clean cloth.

Tensioning Bracket And Spring:

5. Pull off tensioning bracket (564), spring (565) with bush (566).

Grinding Chain Links:

6. Grind open both rivet link pins (arrows) on a double link of the oil pump chain (610). Press out ground open double link.

NOTE: Do not take oil pump chain off the oil pump drive gear, tie on left and right with wire.

Marking Chain Position:

7. Mark position of timing chain (66) relative to camshaft gear (19) with a colored pen. Take timing chain off camshaft gear (19) in direction of arrow.

Pulling Crankshaft Gear:

8. Pull off crankshaft gear (73) with puller 615 589 O1 33 00.

INSTALLATION
1. Heat crankshaft gear to approx. 50 °C (122°F) and fit onto the crankshaft.

NOTE: Pay attention to the Woodruff keys.

2. Fit timing chain onto the camshaft gear.

NOTE: Pay attention to colored marking.

3. Fit oil pump chain onto the crankshaft gear. Insert rivet link from behind into the oil pump chain.

Chain Rivet Tool:

12. Insert thrust piece (03) into the rivet tool as shown in the drawing and tighten with the screw (arrow).

NOTE: The figure 2 is stamped on the side of the thrust piece (03).

Rivet Tool Moving Jaw:

13. Insert moving jaw (02) with the figure 2 into the rivet tool as shown in the drawing.

Inserting Plate:

14. Insert plate (arrow) into the moving jaw (02) (magnetic surface).

Chain Breaker:

15. Fit web (arrow) onto both rollers on the link.

NOTE: Rivet heads of rivet link pins must be guided in the slot (C).

Breaking Chain:

16. Screw in spindle (04) until a firm resistance is felt.

NOTE: When screwing in, ensure that the pins of the link are inserted into the holes of the plate.

Changing Moving Jaw:

17. Take off rivet tool and change over the moving jaw (02) to the rivet profile (D).

Breaking Chain:

18. Fit on rivet tool. Rivet pins of the rivet link individually, by tightening the spindle (04) to 30 Nm (22 ft lbs).
19. Check riveting; re-rivet if necessary.
20. Install spring, bush and tensioning bracket.
21. Install tensioning rail.
22. Install in the reverse order. Check for leaks with engine running.