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Replace timing chain - AR05.10-P-7601GZB: Notes

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ENGINE 642 in MODEL 164 

Fig 1: Replacing Timing Chain (1 Of 2)
G06877973Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Replacing Timing Chain (2 Of 2)
G06877974Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Removing     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
1 Remove strut tower brace Model 164.8 only
IMPORTANT Remove spring dome strut at spring dome mounts.		 AR62.30-P-2500GY
2 Remove engine trim panel IMPORTANTInstallation:  Reinstall the engine cover only after the engine has been checked for oil leaks.  
3 Remove right cylinder head cover   AR01.20-P-5014GZB
4 Fit holddown device kit at the camshafts SPECIAL TOOL Hold-down device kit Fig 15
5 Unscrew bolt (6) for camshaft sprocket IMPORTANT The bolt (6) is located opposite locking pin (5) for the right intake camshaft.  
6 Position piston of cylinder 1 to ignition TDC IMPORTANT Crank the engine at the crankshaft in the running direction. The markings on the camshaft sprockets must lie opposite each other and the markings on the ring gear of the camshaft sprockets must be aligned with the cylinder head.
IMPORTANT The TDC marking of the vibration damper must be aligned with the bar of the timing case cover.		 AR05.10-P-6858GZB 
7 Fix old timing chain (1) with a cable tie (7) to camshaft sprocket    
8 Remove chain tensioner   AR05.10-P-7800GZB 
9 Unscrew bolts (3, 4) from the camshaft sprocket    
10 Dismount the holddown device kit from the camshafts SPECIAL TOOL Hold-down device kit Fig 15
11 Remove the right intake camshaft   AR05.20-P-6992OM 
12 Disconnect old timing chain (1) NOTES Cover over timing case recess with a clean cloth. Parts, which have fallen into timing case recess, must be removed, in order to avoid damage to the engine. AR05.10-P-7601-01PI 
SPECIAL TOOL Case Fig 7
SPECIAL TOOL Chain separating tool Fig 8
SPECIAL TOOL Pressure screw Fig 13
SPECIAL TOOL Thrust pins Fig 14
13 Check camshaft sprocket INSPECT Check camshaft sprocket for wear or damage. Replace if necessary.  
14 Fit right intake camshaft   AR05.20-P-6992OM 
15 Fit holddown device kit at the camshafts SPECIAL TOOL Hold-down device kit Fig 15
16 Screw on camshaft sprocket IMPORTANT Just secure camshaft sprocket with one bolt.  
TORQUE SPECIFICATION *BA05.10-P-1004-01L 
17 Screw holddown device (8) onto the new timing chain (2) at the right cylinder head SPECIAL TOOL Holddown device Fig 16
18 Draw in new timing chain (2) NOTES Replace assembly clip-type fastener (7.1), the outer assembly plate (7.2) and the assembly locking element (7.3) after fitting the new timing chain (2) with a rivet link, otherwise the new timing chain (2) could rip when the engine is running, leading to engine damage.
IMPORTANT To draw in the new timing chain (2), crank engine in direction of rotation at the crankshaft.
IMPORTANT To pull out old timing chain (1), connect old timing chain (1) to new timing chain (2).
IMPORTANT Remove cable tie (7) before cranking the engine.		 AR05.10-P-7601-04PI 
SPECIAL TOOL Case Fig 7
SPECIAL TOOL Assembly links Fig 9
SPECIAL TOOL Holddown device Fig 16
19 Dismount holddown device (8) from new timing chain (2) at right-hand cylinder head SPECIAL TOOL Holddown device Fig 16
REMOVING Install     
20 Dismount holddown device kit from camshafts SPECIAL TOOL Hold-down device kit Fig 15
21 Fix new timing chain (2) with a cable tie (7) to camshaft sprocket    
22 Remove right intake camshaft   AR05.20-P-6992OM 
23 Rivet new timing chain (2) NOTES Cover over timing case recess with a clean cloth. Parts, which have fallen into timing case recess, must be removed, in order to avoid damage to the engine. AR05.10-P-7601-02PI 
TORQUE SPECIFICATION *BA05.10-P-1005-01L 
SPECIAL TOOL Assembly inserts Fig 5
SPECIAL TOOL Riveting tool Fig 6
SPECIAL TOOL Case Fig 7
SPECIAL TOOL Assembly inserts Fig 10
SPECIAL TOOL Thrust piece Fig 11
24 Fit right intake camshaft   AR05.20-P-6992OM 
25 Fit holddown device kit at the camshafts SPECIAL TOOL Hold-down device kit Fig 15
26 Installing chain tensioner   AR05.10-P-7800GZB 
27 Crank engine in direction of rotation IMPORTANT Remove cable tie (7) before cranking the engine.  
28 Check timing of engine   AR05.10-P-6858GZB 
SPECIAL TOOL Retaining pins Figure
SPECIAL TOOL Retaining lock Fig 4
29 Install the right cylinder head cover   AR01.20-P-5014GZB
DANGER 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 engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
30 Check for leaks with engine running
31 Reinstall engine cover    
32 Install spring dome strut Model 164.8 only
IMPORTANT Install spring dome strut at spring dome mounts.		 AR62.30-P-2500GY
TIMING CHAIN, CHAIN TENSIONER

Number Designation Engine 642
BA05.10-P-1004-01L Bolt connecting camshaft sprocket to camshaft Nm 18
BA05.10-P-1005-01L Bolt for timing chain rivet element (reference value) Nm 32
Fig 3: Identifying Retaining Pins (111 589 03 15 00)
G06877975Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Retaining Lock (112 589 03 40 00)
G06877976Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Assembly Inserts (112 589 09 63 00)
G06877977Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Riveting Tool (602 589 00 39 00)
G06877978Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Case (602 589 00 98 00)
G06877979Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Chain Separating Tool (602 589 02 33 00)
G06877980Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Assembly Links (602 589 02 40 00)
G06877981Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Identifying Assembly Inserts (602 589 02 63 00)
G07541630Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 11: Identifying Assembly Inserts (602 589 03 63 00)
G06877982Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 12: Identifying Thrust Piece (602 589 03 63 00)
G06877983Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 13: Identifying Thrust Spindle (602 589 04 63 00)
G06877984Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 14: Identifying Thrust Pins (602 589 04 63 01)
G06877985Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 15: Identifying Hold down Device Kit (642 589 00 31 00)
G06877986Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 16: Identifying Hold down Device (642 589 01 40 00)
G06877987Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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