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How to Replace timing chain on Mercedes E200 CDI W211 2002-2008

Special tools

  • Camshaft locking pin – No.111589031500.
  • Flywheel/drive plate locking tool (bell housing) – No.601589024000.
  • Bolts for flywheel/drive plate locking tool – M6 x 90 mm.
  • Flywheel/drive plate locking tool (starter motor aperture) – No.602589004000.
  • Timing chain link kit – No.602589024000.
  • Timing chain link separator (item 1) – No.602589023300.
  • Timing chain link separator (item 2) – No.602589046300.
  • Timing chain link separator (item 3) – No.602589046301.
  • Timing chain link installer – No.602589003900.
  • Timing chain link installer die kit 1 – No.602589026300.
  • Timing chain link installer die kit 2 – No.602589036300.
  • Timing chain link installer die kit 3 – No.112589096300.
  • Tool case – No.602589009800.
  • Holding tool – No.611589014000.

General precautions

  • Disconnect battery earth lead.
  • Remove fuel injectors to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • Observe tightening torques.
  • Do NOT turn crankshaft via camshaft or other sprockets.
  • Do NOT turn crankshaft or camshaft with timing chain removed.
  • Do NOT turn crankshaft or camshaft with locking pin installed.

Valve timing procedures

How to Replace timing chain on Mercedes E200 CDI W211 2002-2008
How to Replace timing chain on Mercedes E200 CDI W211 2002-2008

NOTE: Timing chain can be changed without dismantling engine. Using the tools listed above, the new chain can be linked to the old, passed round the sprockets and then joined.

  • Engine at TDC on No.1 cylinder [1] .
  • Insert locking pin into inlet camshaft sprocket [2] .
  • Ensure timing marks on each camshaft aligned [3] & [4] .
  • Remove tensioner assembly before carrying out engine repairs [5] .

NOTE: Bolts for camshaft sprocket MUST be renewed [6] .

  • Install tensioner after engine repairs [5] . Tightening torque: 80 Nm.
  • Tighten crankshaft pulley bolt [7] :
      • Bolt classification 8.8 – 200 Nm + 90°.
      • Bolt classification 10.9 – 325 Nm + 90°.
      • 646.820/821: 200 Nm + 90° + 90°.
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