AR05.10-P-7601AV Replace the Timing Chain

Replace Timing Chain







Remove

DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury glasses to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.



1 Disconnect ground cable
2 Remove spark plugs

NOTE:
- 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 one spark plug at each cylinder.

3 Remove cylinder head covers
- Air cleaner mounted on vehicle.
- Air cleaner positioned at engine side.

4 Remove viscous fan

NOTE: Right-hand thread!

5 Remove fan shroud

NOTE: On model 163 unscrew bolts at bottom of fan shroud.

6 Position engine to 40 degrees ATDC of the first cylinder.

CAUTION:
- Engine must not be cranked back.
- The notches of the camshafts must point toward 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

NOTE:
- The copper tabs of the timing chain must be aligned with the markings 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 until the copper tabs are matched 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 Gasket of combination valve.

7 Remove chain tensioner
8 Remove camshaft position sensor
9 Crank engine in direction of rotation until the link for separating the timing chain is easily accessible

NOTE: Timing chain is separated one chain link next to the copper plate (on right). See new timing chain.

10 Remove camshaft bearing bridge on right
11 Install holding bush (3) onto camshaft on right

NOTE: Screw in bolts (4) only until they touch.

12 Attach retaining devices (1, 2) for timing chain to right and left cylinder head
13 Separate timing chain

NOTE:
- Parts which have dropped into the timing case recess, must be removed. Cover over timing case recess with a clean cloth.
- Connect old timing chain to new timing chain before pulling out.
Install
14 Draw in new timing chain

NOTE: To draw in the new timing chain, crank engine in direction of rotation at the crankshaft.

15 Remove retaining devices (1, 2) for timing chain at right and left cylinder head
16 Rivet new timing chain
17 Crank engine in direction of rotation
18 Check timing of engine
19 Take off holding bush (3) on right camshaft
20 Install camshaft bearing bridge on right
21 Install camshaft position sensor
22 Installing chain tensioner
23 Install fan shroud
24 Install viscous-drive fan

NOTE: Right-hand thread!

25 Install cylinder head covers
- Air cleaner mounted on vehicle.
- Air cleaner positioned at engine side.

26 Install spark plugs
27 Connect ground cable

DANGER:
- Risk of accident from vehicle starting off by itself when engine running. Risk of injury as working around the engine during startup or while running may result in contusions and burns
- Secure vehicle to prevent it from moving.
- Wear closed and tight-fitting work clothes.
- Do not grasp hot or rotating parts.

28 Run engine and inspect for leaks.