Installation and Riveting of Timing Chain Procedure

1. Remove Visco fan. (see SMS, models 201, 124 and 140: Engines 601, 602, 603, Mechanical IV, Job No. 20-312). (see SMS, models 124, 210: Engines 604, 605, 606, Mechanical II, Job No. AR20.40-5660HB).

2. Remove timing chain tensioner. (see SMS, models 201, 124 and 140: Engines 601, 602, 603, Mechanical III, Job No. 05-310). (see SMS, models 124, 210: Engines 604, 605, 606, Mechanical II, Job No. AR05.10-7800HA).

3. Disconnect and partially unscrew all glow plugs.

4. Remove valve cover.

Separating timing chain





As shown on engines 601 to 603

5. Attach retainer (01, Figure 1) Special Tool 602 589 01 40 00 on engines 601 - 603 or Special Tool 602 589 00 40 00 on engines 604 - 606, to cylinder head with bolts as shown (arrows, Figure 1).

6. Cover exposed timing chain case with a clean shop towel.





7. Install link remover mandrel (02, Figure 2) Special Tool 602 589 04 63 00 along with link removal pin, Special Tool 602 589 04 63 01 into link removal tool (03, Figure 2) Special Tool 602 589 02 33 00.





8. Lay above assembled link removal tool (03) onto the timing chain (Figure 2) and contact the leading link pin (Figure 3).

9. Using a wrench, turn link remover mandrel (02) in towards the timing chain until contact is made with the timing chain link plate (Figure 2).

10. Continue by turning mandrel (02a) (with link removal pin) (Figure 2) to press out the timing chain leading link pin from the old timing chain (Figure 3).





11. Unscrew link remover mandrel (02) and then remove link removal tool (03) from old timing chain (Figure 4). The timing chain is now separated.

12. Remove pressed out timing chain link pin (1) from link removal tool (03) (Figure 4).

Installing new timing chain





13. Connect new timing chain (5, Figure 5) to the old timing chain (4, Figure 5) using the suitable threading link (04) from Special Tool 602 589 02 40 00.

14. Using a ratchet and socket on the crankshaft, carefully turn engine in direction of rotation, thereby rolling in the new chain (5, Figure 5) onto all the sprockets (in place of the old timing chain) while removing the old chain at the same time.

! IMPORTANT!
Do not rotate engine backwards. Apply pulling tension on old timing chain while feeding in new timing chain to ensure new timing chain properly engages all sprockets. Retainers (602 589 01 40 00 and 604 589 00 40 00) prevent the timing chain from jumping from cam sprocket, thus eliminating the assistance of a second technician when feeding in the timing chain.





15. Disconnect old timing chain (4) from new timing chain (5) when the threading link (04) has reached the top of the camshaft sprocket (Figure 6). Remove and discard old timing chain.

! IMPORTANT!
Threading link (04), Special Tool 602 589 02 40 00 is considered a temporary assembly aid only and must be removed after use.

Riveting new timing chain connecting link





16. Connect the two timing chain ends (5, Figure 7) using the assembly link, Special Tool 602 589 02 63 00 (05, Figure 7) and also from the new timing chain insert the new connecting link center link plate (2, Figure 7).

! IMPORTANT!
Insert assembly link (05) as shown, since it will be pushed back out by the link assembly tool when new timing chain connecting link is installed in step 20.

The assembly link (05), Special Tool 602 589 02 63 Do is considered a temporary assembly aid only and must be removed after use.





17. Attach swaging jaws (F5 and D9, Figure 8), Special Tool 602 589 02 63 00 into link assembly tool (06).

18. Insert new timing chain connecting link (3, Figure 8) into timing chain ends (5). Observe direction of installation.

19. Lay link assembly tool (06) onto timing chain (5, Figure 8).

20. Press in new timing chain connecting link (3, Figure 8) by turning link assembly tool mandrel (07, Figure 8).

NOTE:
Assembly link (05) will be pushed out in forward direction (arrow, Figure 8), when pressing in new timing chain connecting link (3, Figure 8).

! IMPORTANT!
The assembly link (05) is considered a temporary assembly aid only and must be removed after use.

21. Remove link assembly tool from timing chain.





22. Attach riveting inserts (D8 and F1) into link assembly tool (06, Figure 9).

23. Insert outer connecting link plate into link assembly tool (06). Outer connecting link plate will be held in place magnetically by link assembly tool. Press outer connecting link plate onto timing chain using mandrel.

24. In order to rivet the timing chain connecting link pins, rotate swaging jaw (D8, Figure 9). Then by turning mandrel carefully rivet the timing chain connecting link pins.





25. Carefully inspect riveted connecting link pins (arrows, Figure 10). If necessary re-rivet pins by repeating step 24 again.

26. Carefully rotate engine by hand to verify camshaft timing. If necessary adjust camshaft timing and injection pump timing.

27. Reinstall timing chain tensioner.

28. Reinstall visco fan.

29. Tighten all glow plugs and reconnect wire harness.

30. Reinstall valve cover.