Removal and installation of the guiding rails A. In cylinder head, B. In timing case - ra05006010341x(0341)

Engines 601, 602 (except 602.98), 603 

Preceding work:

Poly-V belt removed (13-345).

Chain tensioner removed (05-310 ).

Operation no. of operation texts and work units or standard texts and flat rates

1. Removal and installation of guiding rail in cylinder head 
   Fig 1: Identifying Guiding Rails Components

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Turbo engines
   Boost air pipe	remove, install.
   Engine 601 in model 202
   Air cleaner cross pipe	remove, install.
   Cylinder head cover (125)	remove, install, bolt (132) 10 Nm.
   With self-levelling suspension:
   Pressure oil pump drive	remove, install (05-437).
   Camshaft timing gear (188)	mark at timing chain. Remove, install camshaft timing gear. Different bolts (190) and washers (189) with different tightening torques. Hexagon bolt 65 Nm. 12-point bolt 25 Nm/90° (05-220) (Numbers 3 - 5).
   Bearing pins (221, 222)	remove, install. Special tools 116 589 20 33 00 and 116 589 01 34 00. Check guiding rail (220), replace if necessary. (Number 6). The extractor 115 589 20 33 00 can be used together with stud 115 589 01 34 00 if the bearing pins have seized.

   TIGHTENING TORQUES AND TIGHTENING ANGLE
   
   

   	Nm
   Hexagon bolts on cylinder head cover	10
   Hexagon bolt on camshaft timing gear	65
   12-point bolt on camshaft timing gear	25	90°

   Special tools 

   Fig 2: Identifying (116 589 20 33 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 3: Identifying (116 589 01 34 00)

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   Fig 4: Identifying (115 589 01 34 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 5: Identifying (001 589 66 21 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 6: Identifying (001 589 72 21 00)

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   Removal 

   1. Remove cylinder head cover.

      With self-levelling suspension: 

   2. Remove pressure oil pump drive (05-437).
   3. Mark relative positions of timing chain and camshaft timing gear.
      Fig 7: Aligning Marks On Timing Chain And Camshaft Timing Gear

      Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   4. Unscrew hexagon bolt or 12-point bolt on camshaft timing gear, holding camshaft with a mandrel.
   5. Remove camshaft timing gear and allow timing chain to sag.

      Note different bolt and washer (05-220).

      Fig 8: Removing Camshaft Timing Gear And Allow Timing Chain

      Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   6. Drive out both bearing bolts with the impact puller 116 589 20 33 00, and 116 589 01 34 00 and remove guiding rail. Check guiding rail and replace if necessary.

      Seized bearing bolts can also be pulled out with puller 115 589 20 33 00 and stud 115 589 01 34 00.

      Fig 9: Identifying Bearing Bolts

      Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

      Installation 

   7. Coat bearing pin collar with sealing compound.
   8. Insert guiding rail and drive home bearing pin with impact puller 116 589 20 33 00 and 116 589 01 34 00.
      Fig 10: Identifying Bearing Bolts

      Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   9. Install camshaft timing gear according to the marking and tighten, noting the color markings.

      Tightening torque and tightening angle

      Hexagon bolt 65 Nm,

      12-point bolt 25 Nm, 90°.

      Fig 11: Aligning Marks On Timing Chain And Camshaft Timing Gear

      Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   10. Position engine on ignition TDC of No. 1 cylinder and check marking (arrows).

       Do not crank engine by camshaft timing gear bolt.

       Fig 12: Locating Marks

       Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

       With self-levelling suspension: 

   11. Install pressure oil pump drive (05-437).
   12. Install cylinder head cover, 10 Nm.

       Preceding work:

       Timing case cover removed (01-210).

       Chain tensioner removed (05-310 ).

2. Removal and installation of guiding rail in timing case 
   Fig 13: Identifying Guiding Rail

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Guiding rail (218)

   pull off from guiding rail bolt (222), put on. Check guiding rail, replace if necessary.

   NOTE: Since 09/86 unhardened straight pins have been fitted for the guiding rail bearing.