Installing Control Chain

NOTIFICATION 

Timing not set correctly 

• Risk of engine damage 
• Rough running engine 
• Loss of engine power 
  1. → Do not use force when fitting the staking tool.
  2. → Make sure that the gap is equal on both sides.
  3. → When inserting the staking tools, do not use force to turn the camshafts against any resistance.
  4. → The engine must be exactly at top dead centre.
  5. → The opposite cylinder must be at ignition TDC.

Information 

The markings on the sprockets and the coloured chain links must match.

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Markings on control chain and sprockets

1. Marking on chain link
2. Marking on sprocket (or cut out or colour coding, depending on type/manufacturer)

1. Lock outlet camshaft.
   1. 1.1  Secure T40271 - camshaft clamp  /1 -1-  to the cylinder head.
   2. 1.2  Turn camshaft gear -2-  with T40266 - adapter-3-  in -Arrow direction A-  until the marking on the camshaft gear -2-  corresponds to the marking on the cylinder head cover.
   3. 1.3  Push T40271 - camshaft clamp  /1 -1-  into the splines of the camshaft gear -2-Arrow B-  .

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   Securing the outlet camshaft

2. Lock intake camshaft.
   1. 2.1  Secure T40271 - camshaft clamp  /2 -1-  on the cylinder head.
   2. 2.2  Turn camshaft gear -2-  with T40266 - adapter-3-  in -Arrow direction B-  until the marking on the camshaft gear -2-  corresponds to the marking on the cylinder head cover.
   3. 2.3  Push T40271 - camshaft clamp  /2 -1-  into the splines of the camshaft gear -2-Arrow A-  .

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   Securing the intake camshaft

   Information 

   Once maximum pointer deflection is reached, the piston is at top dead centre (TDC). 

3. Move first cylinder to TDC position.
   1. 3.1  Turn crankshaft slowly in direction of rotation of the engine until maximum deflection of the pointer on the VAS 6079 -dial gauge-2-  is reached.

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   Dial gauge on cylinder 1

4. Fit camshaft control chain.
   1. 4.1  Position camshaft control chain with the coloured chain link facing the marking on the crankshaft gearwheel.
   2. 4.2  Fit camshaft control chain on the camshaft gears such that the coloured chain links are aligned with the markings -1-  on the camshaft gears. Turn the camshafts slightly using T40266 - adapter  if necessary.
   3. 4.3  Check that markings -1-  are still aligned with markings -2-  .
   4. 4.4  Using the VAS 6079 - dial gauge  , check that the first cylinder is still in TDC. 
   5. 4.5  Only if timing is not OK:

      Remove control chain and repeat steps 4.1 to 4.4.

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      TDC markings on crankshaft and camshafts

5. Secure the guide and tension rail.
   1. 5.1  Secure the tension rail -2-  .
      1. 5.1.1  Position tension rail -2-  .
      2. 5.1.2  Screw in and tighten guide pin -4-  .

      > Tightening - torque 20 Nm (15 ftlb.) 

   2. 5.2  Install guide rail -1-  .
      1. 5.2.1  Position the side guide rail -1-  .
      2. 5.2.2  Screw in and tighten guide pin -3-  .

         > Tightening - torque 20 Nm (15 ftlb.) 

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   Guide and tension rail

6. Fit upper guide rail -1-  .

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   Upper guide rail

7. Remove T40267 - staking tool-2-  from the chain tensioner -1-  .

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   Chain tensioner latch

8. Install chain tensioner for oil pump -1-  .
   1. 8.1  Position oil pump chain tensioner -1-  .
   2. 8.2  Screw in and tighten guide pin -2-  .

      > Tightening - torque 9 Nm (6.5 ftlb.) 

   3. 8.3  Remove T40011 - staking pin-3-  .

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   Chain tensioner for oil pump

9. Remove T40271 - camshaft clamp /1  and T40271 - camshaft clamp /2. 
   1. 9.1  Use T40266 - adapter  to relieve intake camshaft and draw T40271 - camshaft clamp /1  out of the splines.
   2. 9.2  Use T40266 - adapter  to relieve outlet camshaft and draw T40271 - camshaft clamp /2  out of the splines.
   3. 9.3  Unscrew and remove T40271 - camshaft clamp /1  and T40271 - camshaft clamp /2. 
10. Turn the engine through two turns and check the timing.

    > WM, 150506 - CHECKING AND SETTING TIMING OF CAMSHAFTS (R4) 

    1. 10.1  If the timing is OK: Remove special tools.
    2. 10.2  If timing is not OK: Set the control timing again.
11. Install bearing saddle -1- 
    1. 11.1  Replace bearing saddle screws -2-  .
    2. 11.2  Fit bearing saddle -1-  and screw in new  bearing saddle screws -2-  hand-tight.
    3. 11.3  Tighten bearing saddle screws -2-  .
       1. 1st Step: > Initial - tightening 4 Nm (3 ftlb.) 
       2. 2nd Step: > Final tightening + 180° 

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    Bearing saddle