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Removal and installation of the crankshaft sprocket - ra03006010350x(0350)

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Engines 601, 602 (except 602.98), 603 

Preliminary jobs:

Timing case cover removed (01-210).

Oil pan removed (01-310).

Vehicles with level control:

Drive for oil pump removed (05-437).

Fig 1: Identifying Crankshaft Sprocket Remove / Install Components
G05438301Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Tensioning bracket (262) remove together with torsion spring (261), install (items 1, 17).
Oil pump sprocket (257) screw out hex. head bolt (259) and remove together with washer (258) (item 2).
Chain for oil pump drive (263) remove (item 3).
Chain tensioner (224) remove, install. Replace sealing ring (237) (05-310) (items 4, 14).
Camshaft sprocket (188) mark in relation to timing chain (210), screw out retaining bolt (190) together with washer (189) and remove camshaft sprocket (items 6 - 8).
 
NOTE: Observe differences in bolts.
Crankshaft sprocket (156) mark in relation to timing chain (210) (item 5).
Crankshaft sprocket (156) pull off with puller 601 589 07 33 00 and check retaining wedge (155a), renew, if required (items 9 - 10).
Crankshaft sprocket (156) renew, transfer color code and knock onto crankshaft with installation punch 116 589 07 15 00 while paying attention to retaining wedge (155a) (items 11 - 12).
Camshaft sprocket (188) position on mark, install timing chain and tighten. Remove hex. head bolts (190) and washers (189). Hex. head bolt 65 Nm, 12-point bolt 25 Nm/90° rotation angle (item 13).
Crankshaft continue to turn and check adjustment markings at TDC position (item 15).
Oil pump sprocket (257) install with chain for oil pump drive (263) and tighten hex. head bolt (259), 25 Nm (item 16).
 
NOTE: Install chain sprocket so that arch points toward oil pump.
Engine allow to run and check for leakage (item 18).

Bolt for camshaft sprocket 

Starting 11/88 the bolt for mounting the camshaft sprocket was changed from an M 10 bolt to an M 11 stretch bolt (see 05-220).

Tightening torques and angles of rotation Nm Angle of rot.
Hex. head bolt for camshaft sprocket 65 -
12-point bolt for camshaft sprocket 25 90°
Hex. head bolt for oil pump sprocket 25 -

Special tools 

Fig 2: Identifying Special Tool (116 589 07 15 00)
G05438302Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Special Tool (102 589 05 33 00)
G05438303Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Special Tool (001 589 72 21 00)
G05438304Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Special Tool (001 589 66 21 00)
G05438305Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal 

  1. Remove clamping bracket (262) and torsion spring (261).
  2. Remove hex. head bolt (259) with washer (258) and remove oil pump sprocket (257).
  3. Remove chain for oil pump drive (263).
  4. Remove chain tensioner (05-310).
    Fig 6: Identifying Clamping Bracket, Torsion Spring And Head Bolt
    G05438306Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Mark position of timing chain and crankshaft sprocket in relation to one another.
    Fig 7: Identifying Mark Position Of Timing Chain And Crankshaft Sprocket
    G05438307Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. Mark position of timing chain and camshaft sprocket in relation to one another.
  7. Screw out hex. head bolt and remove with washer.
  8. Remove camshaft sprocket and allow timing chain to sag.
    Fig 8: Identifying Camshaft Sprocket And Timing Chain
    G05438308Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Pull off crankshaft sprocket with puller 102 589 05 33 00
  10. Check condition of retaining wedge in crankshaft, renew, if required.
    Fig 9: Pulling Crankshaft Sprocket With Puller
    G05438309Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Installation 

  11. Transfer color code from old crankshaft sprocket to new crankshaft sprocket.
  12. Knock crankshaft sprocket onto crankshaft with installation punch 116 589 07 15 00. Pay attention to retaining wedge.
    Fig 10: Installing Knock Crankshaft Sprocket And Crankshaft
    G05438310Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  13. Install camshaft sprocket and timing chain paying attention to marking and tighten.

    Tightening torque and rotation angle

    Hex. head bolt 65 Nm,

    12-point bolt 25 Nm, 90°.

  14. Install chain tensioner and renew sealing ring (05-310).
  15. Continue to turn crankshaft and check adjustment marking at TDC (arrows).
    Fig 11: Locating Camshaft Sprocket And Timing Chain
    G05438311Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Install chain for oil pump drive together with oil pump chain sprocket and tighten.
    NOTE: Install oil pump sprocket so that arch points toward oil pump (arrows).

    Tightening torque 25 Nm.

    Fig 12: Locating Pump Drive And Oil Pump Chain Sprocket
    G05438312Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  17. Attach clamping bracket (262) and torsion spring (261).
  18. Run engine and check for leaks.
Fig 13: Identifying Clamping Bracket And Torsion Spring
G05438313Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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