Removal and Replacement
Timing Chain Replacement and RivetingProceeding work
Spark plugs removed. Refer to Powertrain Management - Ignition System - Spark Plug - Service and Repair - Procedures Service and Repair
Replacing and riveting timing chain
NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.
1. Remove chain tensioner. Refer to Timing Components - Timing Chain Tensioner - Service and Repair - Procedures - Removing and Installing Chain Tensioner Service and Repair
2a. On engines with HT distributor, remove top guide rail. Refer to Timing Components - Timing Cover - Service and Repair - Procedures Service and Repair
2b. On engines without HT distributor, remove front cover and top guide rail. Refer to Timing Components - Timing Cover - Service and Repair - Procedures Service and Repair
3. Cover chain box with clean cloth.
4. Grind open pins of timing chain link (arrows) over camshaft sprocket (9). Separate with chain separating tool 602 589 02 33 00 and thrust spindle 602 589 04 63 00 (2.9 mm).
5. Pry off plate (8) of timing chain (4) with screwdriver.
6. Press out ground open double link.
7. Connect new timing chain (5) to old timing chain (4) with riveted link (6) and centre plate (7) (thickness 1.6 mm) and ground open outer plate (8).
8. Rotate crankshaft with wrench socket insert in direction of rotation of engine.
NOTE: Pay attention to different lengths of timing chains.
Engines 104.980/981 use chains of 130 links.
Engines 104.94/99 (2.8/3.6L and 3.2L) use chains of 126 links
9. Pull in new separated timing chain (5).
10. Hold timing chain meshed at exhaust camshaft sprocket (9) by hand when pulling in.
11. Pull out bottom free end (4) of timing chain from chain box.
12. Rotate crankshaft sufficiently until the end of the new timing chain can be connected with the riveted link.
13. Connect new timing chain (5) to inserted link (6) and center plate (7).
NOTE: Riveted links of the IWIS version chain should be matched to the IWIS timing chain and riveted links of the Renold version chain should be matched to the Renold timing chain. The identifications are stamped in each case on the outer plates of the timing chain.
14. Insert jaw for duplex roller chain with insert 1 into pressing on tool and screw on with screw (28) (Fig. A).
15. Insert moving thrust piece for simplex roller chain with the insert 2 into pressing-on tool (Fig. B).
16. Insert outer plate (8) of 1.2 mm thickness into moving thrust piece (Fig. C).
17. Fit webs (arrows) onto rollers at riveted link (Fig. D).
18. Screw in spindle (04) until tight resistance felt (Fig. D). When screwing in, ensure that the pins of the riveted link are inserted into the holes of the outer plate (8).
19. Take off pressing-on tool.
20. Turn over moving thrust piece with the insert 2 (riveting profile) (Fig. E).
21. Position pressing-on tool exactly over middle of pin (Fig. F).
22. Tighten spindle (04) to 30 Nm (Fig. 5).
23. Rivet pins of inserted link (6) individually.
24. Inspect riveting. Re-rivet if necessary (Fig. G).
25. Adjust basic position of camshafts. Refer to Camshaft, Engine - Adjustments Adjustments
26. Install front cover and top guide rail. Refer to Timing Components - Timing Cover - Service and Repair - Procedures Service and Repair
27. Install chain tensioner. Refer to Timing Components - Timing Chain Tensioner - Service and Repair - Procedures - Removing and Installing Chain Tensioner Service and Repair
29. Check basic position of camshafts. Refer to Camshaft, Engine - Testing and Inspection - Procedures Testing and Inspection