Página 1/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet

Remove the air filter

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Disconnect the crankcase breather hose

Disconnect the Hall sensor

Disconnect the shut-off valve electrical connector

Unclip the wiring loom

 Página 2/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Move the harness
Warnings aside
and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

Disconnect the injector wiring
General
Remove the injection lines
Before disconnecting the battery cable, check the audio system security code
Remove the fuel injector clamps
Check the timing marks before timing chain removal
Remove the injectors

Use the special tools 602 589 00 33 00, 611 589 00 33 00

Remove the cylinder head cover

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Disconnect the vacuum hose from the vacuum pump

Remove the vacuum pump

Remove the air inlet

Remove the air filter

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Remove the lower guard

Drain the coolant

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MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Disconnect
Warningstheandradiator hoses
recommendations 1, 2

Unless otherwise
Disconnect the inside
advised
bonnet
by the
release
manufacturer,
cable the following procedures are recommended: 3

Always
Removerenew
the radiator
the timing
crosschain
member 4

If the timingthe
Disconnect chain
fan is
electrical
to be re-used,
connections
mark the running direction before removal

Never turn
Remove thethe
cooling
enginefan
in the direction opposite to that of normal operation 5

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Turn the crankshaft to TDC for cylinder 1

Lock the inlet camshaft gearwheel

Use the locking pins 111 589 03 15 00

Removal
Disconnect
Check the timing
the battery
marksearth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the chain tensioner

Remove the air inlet

Remove the air filter

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 Página 4/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting
Secure the chain the battery cable, check the audio system security code

Check
Use thethe timing
special marks
tool before
611 timing
589 01 chain removal
40 00

Separate the timing chain

Use the special tools to remove the timing chain pins 602 589 02 33 00, 602 589 04 63 00, 602 589 04 63 01

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

the special
Remove the coverstools 602 589 02 33 00, 602 589 04 63 00, 602 589 04 63 01

Pull the removed timing chain pins out of the chain separating tool

Installation
Connect the old chain to the new one
Remove the air tools
Use the special inlet 602 589 02 40 00
Remove the air filter
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 Página 5/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Remove the camshaft locking pin 111 589 03 15 00

Turn the engine until the chain connecting link shows

Disconnect the chain

Connect the ends of the new chain

Use the special tools 602 589 00 39 00, 602 589 03 63 00

602 589 02 63 00, 112 589 09 63 00

Installation sequence: A -> H

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet

Remove the air filter

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 Página 6/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet E

Remove the air filter
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 Página 7/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code F
Check the timing marks before timing chain removal

G
Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet

Remove the air filter

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Remove the special tool 611 589 01 40 00

Fit the chain tensioner

Renew the seal

Tighten the tensioner body 80 Nm

 Página 8/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Beforethe
Turn disconnecting
crankshaft totheTDC
battery cable, check
for cylinder 1 the audio system security code

Check
Fit the the timinglocking
camshaft marks tool
before 111
timing
589chain
03 15removal
00

Check the camshaft timing marks

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

If the marks are misaligned

Remove the camshafts

Fit the camshafts

Check the timing marks again

Remove the air inlet

Remove the air filter

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 Página 9/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Remove the camshaft locking tools 111 589 03 15 00

Fit the cooling fan 5

Reconnect the fan electrical connections

Refit the cross member 4

Refit the bonnet lock release cable 3

Refit the radiator hose(s) 1, 2

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Refill the cooling system

Cooling system 12.4 (l)

Cooling system:12.4 (l)

Datos de ajuste(Capacities)

Refit the lower guard

Fit the vacuum pump 14 Nm

Renew the seals

Reconnect the vacuum hose to the vacuum pump

Remove the air inlet

Remove the air filter

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 Página 10/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code
Refit the cylinder head cover
Check the timing marks before timing chain removal
Renew the gaskets

Tighten the bolts by hand

Refit the injectors

Renew the seals

Removal
Apply sealant
Disconnect the battery earth cable
Note:Battery:
Refit theprocedures
injectors infortheir original cylinder
disconnection/reconnection
Renew the bolt(s)
Remove the covers
Refit the fuel injector clamps 7 Nm + 90°

Refit the injection lines 23 Nm

Reconnect the fuel injector wiring

Tighten the cylinder head cover bolts 9 Nm

Remove the air inlet
Refit the wiring loom to the cylinder head
Remove the air filter
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 Página 11/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Reconnect the shut-off valve electrical connector
Always use new gaskets
Reconnect the Hall sensor wiring
General
Reconnect the crankcase breather hose
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Refit the air filter

Refit the air inlet

Refit the covers 10 Nm

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Reconnect the battery earth cable

Torque settings
Cover: 10 Nm

Remove the air inlet

Remove the air filter

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 Página 12/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

Cylinder head cover 9 Nm

Clamp 7 Nm + 90°

Fuel lines: crown nuts 23 Nm

Chain tensioner 80 Nm

Vacuum pump: 14 Nm

Special tools
Camshaft locking pins: 111 589 03 15 00

Timing chain holding tool: 611 589 01 40 00

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Timing chain separating tools: 602 589 02 33 00, 602 589 04 63 00, 602 589 04 63 01

Remove the air inlet

Remove the air filter

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Timing chain assembly links: 602 589 02 40 00

 Página 13/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Timing chain assemblythe
Before disconnecting tools:
battery602 589 check
cable, 00 39 the
00, audio
602 589 03 63security
system 00 code

Check the timing marks before timing chain removal

602 589 02 63 00, 112 589 09 63 00

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet

Remove the air filter

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Extractor: 602 589 00 33 00, 611 589 00 33 00
 Página 14/14

MERCEDES-BENZ CLK (W209)270 CDI 612.967

2002 - 2005

Timing chain: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always renew the timing chain

If the timing chain is to be re-used, mark the running direction before removal

Never turn the engine in the direction opposite to that of normal operation

Note: Avoid bending, torsion or traction

Always use new gaskets

General
Before disconnecting the battery cable, check the audio system security code

Check the timing marks before timing chain removal

©HaynesPro B.V. ©HaynesPro B.V.

Removal
Disconnect the battery earth cable

Battery: procedures for disconnection/reconnection

Remove the covers

Remove the air inlet

Remove the air filter

©HaynesPro B.V. Powered by Haynes Pro 2016