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

ENGINE 112 

ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250 

ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254 

ENGINE 113.982 in MODEL 463.243/246 

ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230 

Fig 1: Identifying Timing Chain 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
	Notes on battery	All models.	AH54.10-P-0001-01A
1	Disconnect ground cable	Model 463 except code (979) Special protection version	AR54.10-P-0003G
		Model 463.241 with code (979) Special protection version.	AR54.10-P-0003PV
		Model 463.248 with code 979	AR54.10-P-0003PM
		Models 129, 208, 210.	AR54.10-P-0003A
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 one spark plug at each cylinder.
	Replace spark plugs	Model 463.	AP15.10-P-1580GA
		Model 129.	AP15.10-P-1580A
		Models 202, 208, 210 with engine 112.
		Models 163.	AP15.10-P-1580GH
3	Remove cylinder head covers	Air filter located at vehicle side.	AR01.20-P-5014B
		Air filter located on engine side.	AR01.20-P-5014BV
4	Remove viscous-drive fan.	Right-hand thread!	AR20.40-P-5660C
5	Remove fan shroud	On model 163 unscrew bolts at bottom of fan shroud. Model 463.	AR20.40-P-6800V
6	Position engine at a 40° crank angle before ignition TDC of cylinder 1.	Engine must not be cranked back. 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 tabs of the timing chain must be aligned with the markings on the camshaft sprockets. Because of the unevenly long travel of the timing chain it may be necessary to crank the engine as much as 14 times until the copper tabs are aligned with the markings 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.
			*BA09.20-P-1001-01D
		Locating plate	Figure
		Locating plate	Figure
	Timing chain drive - general		GF05.10-P-9611-01C
7	Remove chain tensioner		AR05.10-P-7800C
8	Remove camshaft position sensor		AR15.10-P-2000A
9	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.
10	Remove camshaft bearing bridge on right	Engine 112, 113.	AR05.20-P-7103AU
		Engine 113.960 with Code (479) cylinder shutoff.	AR05.20-P-7103AV
11	Install holding bush (3) onto camshaft on right	Insert bolts (4) only until they make contact.
			Figure
12	Bolt on holding devices (1, 2) for timing chain at right and left cylinder heads		Figure
13	Separate timing chain	Parts which have dropped into the timing case recess, must be removed. Cover over timing case recess with a clean cloth.	AR05.10-P-7601-01AV
		Connect old timing chain to new timing chain before pulling out.
	Installing
14	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
15	Remove retaining devices (1, 2) for timing chain at right and left cylinder head		Figure
16	Rivet new timing chain		AR05.10-P-7601-02AV
17	Crank engine in direction of rotation
18	Check timing of engine		AR05.10-P-6858V
19	Take off holding bush (3) on right camshaft		Figure
20	Install camshaft bearing bridge on right	Engines 112, 113.	AR05.20-P-7103AU
		Engine 113.960 with code (479) Cylinder shutoff.	AR05.20-P-7103AV
21	Install camshaft position sensor		AR15.10-P-2000A
22	Installing chain tensioner		AR05.10-P-7800C
23	Install fan shroud	Model 463.	AR20.40-P-6800V
24	Install viscous-drive fan	Right-hand thread!	AR20.40-P-5660C
25	Install cylinder head covers	Air filter located at vehicle side.	AR01.20-P-5014B
		Air filter located on engine side.	AR01.20-P-5014BV
26	Install spark plugs
	Replace spark plugs	Model 463.	AP15.10-P-1580GA
		Model 129.	AP15.10-P-1580A
		Models 202, 208, 210 with engine 112.
		Models 163.	AP15.10-P-1580GH
27	Connect ground cable	Model 463 except code (979) Special protection version	AR54.10-P-0003G
		Models 463.241 with code (979) Special protection version.	AR54.10-P-0003PV
		Model 463.248 with code 979	AR54.10-P-0003PM
		Models 129, 208, 210.	AR54.10-P-0003A
	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
28	Run engine and inspect for leaks

INTAKE MANIFOLD

Fig 2: Identifying Locating Plate (112 589 00 32 00)

Fig 3: Identifying Locating Plate (112 589 01 32 00)

Fig 4: Identifying Retainer (112 589 04 40 00)

Fig 5: Identifying Holding Bush (112 589 05 40 00)