Figure 5.16. Replacing the timing chain:
1. Cylinder head cover,
2. Timing chain tensioner,
3. Sealing,
4. Fuel pump,
5, 7, 10. Bolts,
6. Front cover,
8. Upper guide lever,
9. Vacuum pump,
11. Guide pin.
2. Disconnect the timing chain. Secure the timing chain 3 to the camshaft pulley 4 using a tension strap (see figure 5.17a).
Figure 5.17a. Fasten timing chain 3 to camshaft pulley 4 using a tension strap.
3. Remove the camshaft pulley 4 together with the attached timing chain 3 (see figure 5.17b).
Figure 5.17 b. Remove the camshaft pulley 4 together with the attached timing chain 3.
4. Screw in the stop spindle 02 (602 589 04 63 00) together with the thrust pin 02a (602 589 04 63 01) in separator 03 (602 589 02 33 00) (see figure 5.17c).
Figure 5.17c. Screw the thrust spindle 02 together with the thrust pin 02a into the separator 03.
5. When installing the thrust spindle, make sure the thrust pin is located on the left side of the chain link pin (arrow) (see page 5.17g).
Figure 5.17d. Make sure that the stop pin is located on the left side of the chain link pin (arrow).
6. Install the separator 1 of the timing chain of the removed camshaft pulley (see figure 5.17d). The timing chain pin can only be removed if the camshaft pulley has been removed.
Figure 5.17d. Install separator 1 of the timing chain of the removed camshaft pulley.
7. Screw in the thrust spindle 2 and disconnect the timing chain.
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8. Unscrew the thrust spindle 2 and remove the separator 1.
9. Install camshaft pulley 4 with chain 3 (see fig.5.17e). Do not remove the chain from the pulley.
Figure 5.17e. Install camshaft pulley 4 with chain 3.
10. Remove the pressed out pin 1 from the separator 03 (see figure 5.17zh).
Figure 5.17g. Remove pressed out pin 1 from separator 03.
11. Install retainer 1 on the cylinder head (see figure 5.18a).
Figure 5.18a. Install retainer 1 on the cylinder head.
12. Remove the timing chain fastening strap.
13. Attach new chain 3 to old chain 2 using link 4.1, plate 4.2 and locking element 4.3 and secure them (see figure 5.18 b).
Figure 5.18 b. Connect new chain 3 to old chain 2 using link 4.1, plate 4.2 and locking element 4.3, and secure them.
14. Install the new chain 3 and rotate the crankshaft slowly in the direction of its rotation until both ends of the new chain 3 are visible (see figure 5.18c).
Figure 5.18c. Install new chain 3 and rotate the crankshaft slowly in the direction of its rotation until both ends of the new chain 3 are visible.
15. Remove the locking element 4.3, the outer plate 4.2, the link 4.1 and disconnect the old chain from the new one (see figure 5.18g).
Figure 5.18g. Remove the locking element 4.3, the outer plate 4.2, the link 4.1 and disconnect the old chain from the new one.
16. Fasten the new chain 3 to the camshaft pulley 5.
17. Insert new link 1 and new middle plate 2 into the end of chain 3 (see figure 5.19a).
Figure 5.19a. Fasten new chain 3 to camshaft pulley 5. Insert new link 1 and new middle plate 2 into the end of chain 3.
18. Remove retainer 4 from the cylinder head.
19. Remove the camshaft pulley 4 with the chain 3 installed on it (see figure 5.19b).
Figure 5.19 b. Remove camshaft pulley 4 with chain 3 installed on it.
20. Place the insert into the riveting tool 5 and secure it (see figure 5.19c).
Figure 5.19c. Install the insert into the riveting tool 5 and secure it.
21. Press the new link 1 into the riveting tool 5 until it stops (see figure 5.19g).
Figure 5.19g. Press new link 1 into riveting tool 5 until it stops.
22. Unscrew the stop spindle and remove the riveting tool 5. Remove the inserts D9 and F5 from the riveting tool.
23. Install insert F1 into riveting tool 2 and secure it with bolt 3 (see figure 5.19d).
Figure 5.19d. Install insert F1 into riveting tool 2 and secure it with bolt 3.
24. Install the D8 insert into the rivet tool 5 (see figure 5.19e).
Figure 5.19e. Install insert D8 into riveting tool 5.
25. Insert the new outer plate 6 into the sliding insert D8 (see figure 5.19zh).
Figure 5.19g. Insert the new outer plate 6 into the sliding insert D8.
26. Install the riveting tool 5 so that the guide rests (arrow) (see figure 5.19z).
Figure 5.19z. Install the riveting tool 5 so that the guide rests (arrow).
27. Screw in the rivet tool spindle until it stops.
28. Remove riveting tool 5.
29. Rotate the D8 insert and position it opposite the rivet profile (arrow) (see figure 5.19k).
Figure 5.19k. Rotate insert D8 and position it opposite the rivet profile (arrow).
30. Install the rivet tool 5 in the middle of the pin (arrow) (see figure 5.19l).
Figure 5.19l. Install riveting tool 5 in the middle of the pin (arrow).
31. Tighten the riveting tool spindle 5 until it stops.
32. Check the rivet (arrows), repeat the riveting process if necessary (see figure 5.19m).
Figure 5.19m. Check the rivet (arrows), repeat the riveting process if necessary.
33. Install the camshaft pulley 7 on the shaft with the chain 3 installed on it (see figure 5.19n).
Figure 5.19n. Install camshaft pulley 7 on the shaft with chain 3 installed on it.
34. Remove the tie straps.
35. Install the timing chain sliding lever.