Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 403

(3) Assemble special tool #9312–1 using 9312– 3

and 9312–4. Install insert #9312–13 and retain with
screw provided. (Fig. 79).

CAUTION: Care must be taken not to drop the tim-
ing chain plates into the engine once the timing
chain is separated.

NOTE: When installing special tool #9312–1 onto
timing chain link, be sure to back off the smaller
nut of the thrust pin #9312–3 until the pin is
recessed inside of the spindle, #9312–4. Screw the
thrust spindle #9312–4 in until it is seated and
aligned properly over the rivet of the timing chain.

NOTE: When fitting the thrust spindle, ensure that
the thrust pin is positioned at the left timing chain
pin of a chain link.

(4) Install special tool #9312 onto timing chain

link (Fig. 79).

NOTE: Cover the timing chain area. Care must be
taken not to drop any repair debris or pieces into
the engine when separating the timing chain links.

(5) Carefully turn the thrust pin #9312–3 of spe-

cial tool #9312–1 clockwise while holding the handle
until the rivet is pressed out and the chain is sepa-
rated (Fig. 80). Discard the loose link and plates.

NOTE: One whole timing chain link must be
removed.

Fig. 78 SPECIAL TOOL 9525

1 - SPECIAL TOOL 9525

Fig. 79 SPECIAL TOOL #9312–1 WITH INSERT

9312–13

1 - SPECIAL TOOL #9312-1
2 - SPECIAL TOOL #9312-13 - INSERT
3 - SPECIAL TOOL #9312-3 - THRUST PIN
4 - SPECIAL TOOL #9312-4 - SPINDLE

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ENGINE

9 - 75

NOTE: Care must be taken not to drop any repair
debris or pieces into the engine when separating
the timing chain links.

(6) Connect new timing chain with the oil holes

facing up, and old timing chain with the assembly
link, assembly plate and locking element, and secure
(Fig. 81).

CAUTION: IT IS ESSENTIAL that the installation pro-
cedure for the timing chain is followed exactly. Fail-
ure to do so will result in severe engine damage.

INSTALLATION

INSTALLATION - TENSIONING AND SLIDE RAIL

NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.

CAUTION: ENSURE THAT THE SPRING IS COR-
RECTLY INSTALLED ON THE TENSIONING CLAMP
AND SLIDE RAIL.

(1) Install rail on bearing pin (Fig. 75).
(2) Install timing cover (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).

(3) Install oil pan bolts. Tighten M6 bolts to 9N·m

(80 lbs.in.) and M8 bolts to 20N·m (15 lbs. ft.).

(4) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).

(5) Reconnect negative battery cable.

Fig. 80 TIMING CHAIN SEPARATION

1 - LEFT TIMING CHAIN PORTION
2 - EXHAUST CAMSHAFT GEAR
3 - RIGHT TIMING CHAIN PORTION
4 - SPECIAL TOOL #9525

Fig. 81 TEMPORARY TIMING CHAIN LINK

1 - TEMPORARY TIMING CHAIN LINK
2 - LEFT TIMING CHAIN PORTION
3 - NEW TIMING CHAIN
4 - SPECIAL TOOL 9525

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ENGINE

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WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(6) Start the engine, allow to warm, turn engine

off and inspect for leaks. Care must be take to
observe the fuel system warning (Refer to 14 - FUEL
SYSTEM - WARNING).

INSTALLATION - INTERMEDIATE GEAR

NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.

(1) Install intermediate gear and bushing. Tighten

bolt to 40N·m (30 lbs.ft.)

(2) Install the intake camshaft (Refer to 9 -

ENGINE/CYLINDER

HEAD/CAMSHAFT(S)

-

INSTALLATION).

(3) Install

exhaust

camshaft

sprocket,

noting

dowel pin alignment. Tighten bolt to 18 N·m (159 lbs.
in.).

WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.

(4) Install high pressure pump (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).

(5) Install top slide rail (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION).

(6) Install cylinder head front cover (Refer to 9 -

ENGINE/CYLINDER HEAD - INSTALLATION).

(7) Install timing chain tensioner with new gasket

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN

AND

SPROCKETS

-

INSTALLA-

TION).

NOTE: Inspect basic position of camshaft and reset
if necessary (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).

(8) Remove camshaft locking pin.
(9) Install cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM

CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.

(10) Install fuel high pressure lines and injectors

(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).

(11) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

(12) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.

(13) Start engine and inspect for leaks. Care must

be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).

INSTALLATION - TIMING CHAIN TENSIONING
RAIL

NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.

(1) Install tensioning rail on bearing pin
(2) Install timing cover (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).

(3) Install oil pan and bolts. Tighten M6 bolts to

9N·m (80 lbs.in.) and M8 bolts to 20N·m (15 lbs. ft.).

(4) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).

(5) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE

IS

OPERATING.

DO

NOT

PUT

YOUR

HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(6) Start the engine and inspect for leaks. Care

must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING).

ADJUSTMENTS

INSTALLATION - TIMING CHAIN

CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.

CAUTION: Cover timing case recesses to prevent
foreign material from entering engine.

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ENGINE

9 - 77

(1) Connect new timing chain, oil hole side up and

old timing chain with the assembly link, the assem-
bly plate and the assembly locking element, and
secure (Fig. 82).

CAUTION: Always install the new timing chain with
the oil holes pointing up. Failure to do so will result
in severe engine damage.

NOTE: Always keep new timing chain meshed with
camshaft sprocket.

CAUTION: DO NOT CRANK ENGINE and DO NOT
ROTATE ENGINE BACKWARD. Engine rotation is
clockwise, as you are looking at the engine. Rotate
engine at crankshaft only.

NOTE: Draw out the end of old timing chain evenly
as it becomes free, to the same extent that new tim-
ing chain is drawn in.

(2) Draw in new timing chain with the oil holes

facing up, by rotating the crankshaft slowly in direc-
tion of rotation of engine. (Fig. 83).

(3)

Rotate the engine until the ends of the new

timing chain meet and can be connected (Fig. 84).

NOTE: Assembly link is only an assembly aid and
NOT designed for engine running.

Fig. 82 OLD AND NEW TIMING CHAIN UNION

1 - TEMPORARY TIMING CHAIN LINK
2 - SPECIAL TOOL 9525
3 - OLD TIMING CHAIN
4 - NEW TIMING CHAIN

Fig. 83 TIMING CHAIN INSTALLATION

1 - NEW TIMING CHAIN
2 - OLD TIMING CHAIN

Fig. 84 TIMING CHAIN ROTATION COMPLETE

1 - NEW TIMING CHAIN
2 - SPECIAL TOOL #9525
3 - TEMPORARY LINK
4 - OLD TIMING CHAIN

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ENGINE

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