Replace timing chain - AR05.10-P-7601R

ENGINE 275 in MODEL 215, 216, 220, 221, 230 

Fig 1: Identifying Timing Chain, Retaining Device And Aspirator Shutoff Valve Hose

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Notes on avoiding damage to ignition system		AH15.10-P-0002-01L
1	Turn key in ignition lock to position "0"	Vehicles with code 889 Keyless-Go: press Start/Stop button repeatedly until ignition is switched off.
2	Remove ground line(s) at battery(ies)	Model 215, 220	AR54.10-P-0003I
		Model 216, 221	AR54.10-P-0003SX
		Model 230	AR54.10-P-0003R
	Notes on battery		AH54.10-P-0001-01A
3	Remove engine trim panel	Engine 275.95	AR01.10-P-2405LA
		Engine 275.98	AR01.10-P-2405IM
4	Remove left and right air filter housing		AR09.10-P-1150LA
5	Remove left and right ignition coil module		AR15.12-P-1100LA
6	Remove cylinder head covers		AR01.20-P-5014H
7	Turn and remove one spark plug from each cylinder	So that engine turns more easily.
	Replace spark plugs	Model 215, 220, 230	AP15.10-P-1580L
		Model 216, 221	AP15.10-P-1580SZ
8.1	Detach coolant expansion reservoir and place to one side with lines connected	Model 230
8.2	Remove washer fluid reservoir of windscreen washer system	Model 215, 220	AR82.35-P-6000M
		Model 216, 221 without top protection	AR82.35-P-6000SY
		Model 221 with code Z07 Top protection	AR82.35-P-6000SX
9	Remove air pump	Model 215, 220	AR14.30-P-7251L
		Model 216, 221	AR14.30-P-7251SZ
		Model 230	AR14.30-P-7251R
10	Remove fan shroud	Model 215.376, 220.176, 230	AR20.40-P-6800AC
		Model 215.379, 220.179	AR20.40-P-6800IM
		Model 216, 221 except 216.379, 221.179	AR20.40-P-6800SZ
		Model 216.379, 221.179	AR20.40-P-6800SXM
11	Position engine to a 30° crank angle after top dead center	Turn engine at crankshaft in the direction of rotation of the engine until the marking 30° CA after TDC at the belt pulley/vibration damper is reached. The engine must not be turned back, otherwise timing chain can skip and this can result in engine damage.
12	Remove chain tensioner	Model 215, 220	AR05.10-P-7800M
		Model 216, 221	AR05.10-P-7800SZ
		Model 230	AR05.10-P-7800R
13	Remove air shutoff valve (1) hose
14	Mount retainer (10) onto right cylinder head	Holding device	*285589014000
15	Disconnect old timing chain		AR05.10-P-7601-01R
		Case	*602589009800
		Chain separating tool	*602589023300
		Thrust spindle	*602589056300
		Pressure pins	*602589056301
	Install
16	Draw in new timing chain		AR05.10-P-7601-04R
		Holding device	*285589014000
		Case	*602589009800
		Assembly links	*602589024000
17	Rivet new timing chain		AR05.10-P-7601-02R
		Case	*602589009800
		Riveting tool	*602589003900
		Thrust spindle	*602589056300
		Assembly inserts	*112589096300
		Assembly inserts	*602589026300
18	Check basic position of camshafts		AR05.20-P-6010MC
19	Remove retainer (10) from right cylinder head	Holding device	*285589014000
20	Mount air shutoff valve (1) hose
21	Install chain tensioner	Model 215, 220	AR05.10-P-7800M
		Model 216, 221	AR05.10-P-7800SZ
		Model 230	AR05.10-P-7800R
22	Install fan shroud	Model 215.376, 220.176, 230	AR20.40-P-6800AC
		Model 215.379, 220.179	AR20.40-P-6800IM
		Model 216, 221 except 216.379, 221.179	AR20.40-P-6800SZ
		Model 216.379, 221.179	AR20.40-P-6800SXM
23	Install air pump	Model 215, 220	AR14.30-P-7251L
		Model 216, 221	AR14.30-P-7251SZ
		Model 230	AR14.30-P-7251R
24.1	Install washer fluid reservoir of windshield washer system	Model 215, 220	AR82.35-P-6000M
		Model 216, 221 without top protection	AR82.35-P-6000SY
		Model 221 with code Z07 Top protection	AR82.35-P-6000SX
24.2	Mount coolant expansion reservoir	Model 230
25	Install spark plugs
	Replace spark plugs	Model 215, 220, 230	AP15.10-P-1580L
		Model 216, 221	AP15.10-P-1580SZ
26	Install cylinder head covers		AR01.20-P-5014H
27	Install left and right ignition coil module		AR15.12-P-1100LA
28	Install left and right air filter housing		AR09.10-P-1150LA
	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.
29	Carry out engine test run, check for oil leakage		AS00.00-Z-0005-01A
30	Fit engine cover	Engine 275.95	AR01.10-P-2405LA
		Engine 275.98	AR01.10-P-2405IM
31	Attach ground line(s) to battery(ies)	Model 215, 220	AR54.10-P-0003I
		Model 216, 221	AR54.10-P-0003SX
		Model 230	AR54.10-P-0003R

Fig 2: Identifying Assembly Links (602 589 02 40 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Holding Device (285 589 01 40 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Case (602 589 00 98 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Chain Separating Tool (602 589 02 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Thrust Spindle (602 589 05 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Thrust Pins (602 589 05 63 01)

Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Assembly Inserts (112 589 09 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 9: Identifying Riveting Tool (602 589 00 39 00)

Courtesy of MERCEDES-BENZ USA

Fig 10: Identifying Assembly Inserts (602 589 02 63 00)

Courtesy of MERCEDES-BENZ USA