Special tools Special tools Crankshaft pulley/hub puller - No.000589653300/000589883300. Crankshaft sprocket puller - No.102589053300. Flywheel/drive plate holding tool - No.901589026300. Flywheel/drive plate locking tool - No.601589024000. Injection pump drive pinion holder - No.602589000700. Injection pump drive pinion puller - No.602589013300. 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 to camshaft sprocket holder - No.602589014000. Tool case - No.602589009800. Viscous coupling pulley holder - No.120589140700. Water pump pulley holder - No.603589004000. General precautions General precautions Disconnect battery earth lead. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). Observe tightening torques. If fitted: Mark position of crankshaft position (CKP) sensor before removal. Do NOT turn crankshaft via camshaft or other sprockets. Do NOT turn crankshaft or camshaft with timing chain removed. Check diesel injection pump timing after resetting valve timing. Valve timing procedures Valve timing procedures 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]. Ensure camshaft timing marks aligned [2]. Remove tensioner assembly before carrying out engine repairs [3]. During removal/installation of injection pump: Crankshaft position set at 12° BTDC on No.1 cylinder [4]. Before installing injection pump, carry out basic setting: Remove coupling sleeve. Turn injection pump pinion until slot [5] aligned with outlet port [6] for No.1 cylinder. Turn pinion clockwise until resistance is felt (start of injection). Install coupling sleeve. Fill chain tensioner with oil before installation: Submerge tensioner vertically in SAE 10 engine oil with plunger pointing downwards. Compress plunger 7-10 times. After filling, ensure tensioner plunger can be compressed slowly and evenly with considerable effort. Install tensioner after repairs [3]. Tightening torque: 80 Nm. Camshaft sprocket bolt MUST be replaced if length 'X' exceeds 53,6 mm [7]. Manufacturer: Mercedes-Benz Engine code: 602.980 Tuned for: Model: Sprinter (901/2/3/4/5) 2,9D 210D Output: 75 (102) 3400 Year: 1997-00 © Autodata Limited 2007 28.06.2011 V6.410- NOTE: Crankshaft pulley central bolt MUST only be used once [8]. Manufacturer: Mercedes-Benz Engine code: 602.980 Tuned for: Model: Sprinter (901/2/3/4/5) 2,9D 210D Output: 75 (102) 3400 Year: 1997-00 © Autodata Limited 2007 28.06.2011 V6.410-