Replacing timing chain - AR05.10-P-7601AA

ENGINE 112,113 / (except, 113.995) Only for vehicles with Electro ventilator

Fig 1: Identifying Timing Chain Removal Components

	Removing
	Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground cable	Do not connect quiescent current retention device otherwise this may cause damage to the control unit.
		Model 203	AR54.10-P-0003P
		Models 129, 163, 170, 202, 208, 210	AR54.10-P-0003A
		Model 209	AR54.10-P-0003Q
		Models 211.061/065/070	AR54.10-P-0003T
		Model 215, 220	AR54.10-P-0003I
		Model 230.474 /475	AR54.10-P-0003R
		All models 463 except 463.241/248 with code 979.	AR54.10-P-0003G
		Model 463.241 with code 979	AR54.10-P-0003PV
		Model 463.248 with code 979	AR54.10-P-0003PM
	Notes on battery	All models	AH54.10-P-0001-01A
2	Remove spark plugs	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 once spark plug of each cylinder.
	Replace spark plugs	Model 163	AP15.10-P-1580GH
		Models 220, 230.474/475	AP15.10-P-1580AB
		Models 210, 208, 202	AP15.10-P-1580A
		Models 203, 170, 209, 211 with engine 112
		Models 209, 211 with engine 113
3	Remove cylinder head covers	Air filter mounted on vehicle	AR01.20-P-5014B
3	Remove cylinder head covers	Air filter mounted on engine	AR01.20-P-5014BV
4.1	Remove fan shroud	Not models 211.061/065/070, 230.475 Models 220, 230.474	AR20.40-P-6800AB
4.2	Remove electric fan	Model 170	AR20.40-P-5000SV
		Models 203, 209	AR20.40-P-5000PV
		Model 163.174	AR20.40-P-5000GH
5	Position engine to 40° after TDC of first cylinder.	Engine must not be cranked backwards. The notches of the camshafts must be pointing in the direction of 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	AR05.20-P-6020AU
		The copper plates of the timing chain must be aligned with the scribe marks 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 till the copper plates get aligned 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 combination valve gasket.
			*BA09.20-P-1001-01D
		Locating plate	Figure
		Locating plate	Figure
	Timing chain drive - general	Engines 112, 113	GF05.10-P-9611-01C
6	Remove chain tensioner	Models 163.174, 215, 220 Models 170, 202, 203, 208.365/465 Models 209, 210, 211061/065/070 Model 230.474 with engine 113.992	AR05.10-P-7800CA
7	Remove camshaft position sensor		AR15.10-P-2000A
8	Crank engine in direction of rotation until the link for separating the timing chain is easily accessible	The separation point for the timing chain is one link down from the copper tab (right). See new timing chain.
9	Remove camshaft bearing bridge on right	Engine 112, 113	AR05.20-P-7103AU
9	Remove camshaft bearing bridge on right	Engine 113.960 with code (479) Cylinder shutoff	AR05.20-P-7103AV
10	Install holding bush (3) onto camshaft on right	Only insert bolts (4) until they make contact. Holding bush	Fig 5
11	Bolt on holding devices (1, 2) for timing chain at right and left cylinder heads	Retainer	Fig 4
12	Disconnect timing chain	Cover over timing case recess with a clean cloth. Parts which have dropped into the timing case recess, must be removed. To pull out the old timing chain, connect the old chain to the new timing chain.	AR05.10-P-7601-01AV
	Install
13	Draw in new timing chain	Pull in the new timing chain by turning the crankshaft in its standard direction of rotation.	AR05.10-P-7601-04AV
		Assembly links	Figure
		Case	Figure
14	Remove retaining devices (1, 2) for timing chain at right and left cylinder head	Retainer	Fig 4
15	Rivet new timing chain		AR05.10-P-7601-02AV
16	Crank engine in direction of rotation
17	Check timing of engine		AR05.10-P-6858V
18	Take off holding bush (3) on right camshaft	Holding bush	Fig 5
19	Install camshaft bearing bridge on right	Engines 112, 113	AR05.20-P-7103AU
19	Install camshaft bearing bridge on right	Engine 113.960 with code (479) Cylinder shutoff	AR05.20-P-7103AV
20	Install camshaft position sensor		AR15.10-P-2000A
21	Installing chain tensioner	Models 163.174, 215, 220 Models 170, 202, 203, 208.365/465 Models 209, 210, 211061/065/070 Model 230.474 with engine 113.992	AR05.10-P-7800CA
22.1	Install fan shroud	Not model 211.061/065/070, 230.475 Models 220, 230.474	AR20.40-P-6800AB
22.2	Install electric fan	Model 170	AR20.40-P-5000SV
		Models 203, 209	AR20.40-P-5000PV
		Model 163.174	AR20.40-P-5000GH
23	Install cylinder head covers	Air filter located at vehicle side.	AR01.20-P-5014B
23	Install cylinder head covers	Air filter located on engine side.	AR01.20-P-5014BV
24	Install spark plugs
	Replace spark plugs	Models 220, 230.474/475	AP15.10-P-1580AB
		Models 210, 208, 202	AP15.10-P-1580A
		Models 170, 203, 209, 211 with engine 112
		Models 209, 211 with engine 113
		Model 163	AP15.10-P-1580GH
25	Connect ground cable	Model 203	AR54.10-P-0003P
		Models 129, 163, 170, 202, 208, 210	AR54.10-P-0003A
		Model 209	AR54.10-P-0003Q
		Models 211.061/065/070	AR61.20-P-1105T
		Model 215, 220	AR54.10-P-0003I
		Model 230.474/475	AR54.10-P-0003R
		All models 463 except 463.241/248 with code 979	AR54.10-P-0003G
		Model 463.241 with code 979	AR54.10-P-0003PV
		Model 463.248 with code 979	AR54.10-P-0003PM
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
26	Run engine and inspect for leaks