Removal and Replacement

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

1. Remove spark plugs.
2. Remove chain tensioner.
3. Remove top guide rail.
4. Cover chain box with clean cloth.





5. Grind off pins of timing chain link (arrows) over camshaft sprocket (9).
- Separate with chain separating tool 602 589 02 33 00 and thrust spindle 602 589 04 63 00, or equivalents.
6. Pry off plate (8) of timing chain (4) with screwdriver.
7. Press out ground open double link.





8. Connect new timing chain (5) to old timing chain (4) with riveted link (6) and centre plate (7) (thickness 1.6 mm) and ground open outer plate (8).
9. Rotate crankshaft with wrench socket insert in direction of rotation of engine.

NOTE:
- Pay attention to different lengths of timing chains.
- Engines 104.94/99 (2.8/3.6L and 3.2L)use chains of 126 links
- Engines 104.980/981 use chains of 130 links.

10. Pull in new separated timing chain (5).
11. Hold timing chain meshed at exhaust camshaft sprocket (9) by hand when pulling in.
12. Pull out bottom free end (4) of timing chain from chain box.
13. Rotate crankshaft sufficiently until the end of the new timing chain can be connected with the riveted link.
14. Connect new timing chain (5) to inserted link (6) and center plate (7).

NOTE: Riveted links of the IWIS version chain should be matched to the IWIS timing chain and riveted links of the Renold version chain should be matched to the Renold timing chain. The identifications are stamped in each case on the outer plates of the timing chain.





15. Insert jaw for duplex roller chain with insert 1 into pressing on tool and screw on with screw (28) (Fig. A).
16. Insert moving thrust piece for simplex roller chain with the insert 2 into pressing-on tool (Fig. B).





17. Insert outer plate (8) of 1.2 mm thickness into moving thrust piece (Fig. C).
18. Fit webs (arrows) onto rollers at riveted link (Fig. D).
19. Screw in spindle (04) until tight resistance felt (Fig. D).

NOTE: When screwing in, ensure that the pins of me riveted link are inserted into the holes of the outer plate (8).

20. Take off pressing-on tool.
21. Turn over moving thrust piece with the insert 2 (riveting profile) (Fig. E).
22. Position pressing-on tool exactly over middle of pin (Fig. F).
23. Tighten spindle (04) to 30 Nm (Fig. 5).
24. Rivet pins of inserted link (6) individually.
25. Inspect riveting.
- Re-rivet if necessary (Fig. G).
26. Adjust basic position of camshafts.
27. Install front cover and top guide rail.
28. Install chain tensioner.
29. Check basic position of camshafts.