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Unread 05-10-2013, 10:51 PM   #31
breckman99
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2007 WK 
 
Join Date: Jul 2012
Location: , CO
Posts: 58
I don't think that is your timing chain. I have a similar sound to my engine with 60k on it and have written it off to the EGR valve. It has made that sound since I bought the jeep. Here is a video:

https://www.youtube.com/watch?v=VCWYQpxImcc

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Unread 05-11-2013, 08:24 AM   #32
suzieque
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2008 WK 
 
Join Date: Mar 2009
Location: Canada
Posts: 1,809
Quote:
Originally Posted by breckman99 View Post
I don't think that is your timing chain. I have a similar sound to my engine with 60k on it and have written it off to the EGR valve. It has made that sound since I bought the jeep. Here is a video:

https://www.youtube.com/watch?v=VCWYQpxImcc
Thanks for posting the video. How many miles on your crd? Have you tried removing the serpentine belt?
__________________
2008 WK "S" Limited bright metallic silver exterior, light graystone interior, 5 speed W5J400 transmission, June 18/2008 build, C213RE rear differential with 3.73 axle ratio, C200FE front differential with 3.73 axle ratio, 245/60R18 Goodyear Fortera tires (stock summer tires), NV245 transfer case, GT2056V turbo, 3.0L CRD (OM642.980)
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Unread 05-11-2013, 10:35 AM   #33
breckman99
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Join Date: Jul 2012
Location: , CO
Posts: 58
suzieque,

The engine currently has 62000 miles and was purchased with 52000. I have not removed the serpentine belt to test for the main bearing tolerance issue.

When I first heard the noise I was alarmed, but after listening to it for awhile it seems like that when it activates, it is either during fueling or above 1500 RPM. You can hear it turn off sharply below 1500 and when below 1500 and lifting the throttle, making it seem like a device on the engine which is turning off and on.

Given the above symptoms I was thinking it was EGR or the high pressure fuel pump and was just going to wait until I remove the EGR when tuned to see if it went away. It does not seem like timing chain slap, as varying the engine at any speed above 1500 RPM does not stop the noise. If it were timing chain slap I'd expect to be able to change the sound of the rattle when rapidly revving the engine at those speeds, its more of a on or off noise.

Now, take this with a grain of salt, as I have not yet had someone operate the fuel pedal while listening to the engine with a stethoscope. I will be doing that soon just in case my above observations and conclusions are incorrect. I just didn't think it sounded like chain slap and was not worried about a external component failing and destroying the whole engine. I'm flying across country tonight so its going to be a few days before I can report back, but I will, as I'm betting tleeming wants this to not be a $4k + job and I sure don't feel like rolling in a new chain already...

Here are some pictures of terror showing the results of a timing chain failure on one of my previous om617 powered cars:

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Unread 05-11-2013, 11:16 AM   #34
suzieque
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Join Date: Mar 2009
Location: Canada
Posts: 1,809
My experience in monitoring egr valve activity suggests the valve closes when the vehicle is parked engine is at operating temperature and idle is raised above 800RPM. Alternatively you can unplug he maf sensor located on the air intake tube just outside the airbox and that will disable egr all the time, but it also triggers a check engine light. Just thought I'd mention that so you could eliminate the egr as being the cause of the noise.
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2008 WK "S" Limited bright metallic silver exterior, light graystone interior, 5 speed W5J400 transmission, June 18/2008 build, C213RE rear differential with 3.73 axle ratio, C200FE front differential with 3.73 axle ratio, 245/60R18 Goodyear Fortera tires (stock summer tires), NV245 transfer case, GT2056V turbo, 3.0L CRD (OM642.980)
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Unread 05-25-2013, 05:27 PM   #35
tleeming
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Join Date: May 2008
Location: British Columbia
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Sorry, been away cruising in Hawaii...I just tried unplugging the conn. in front of the air box...no change in rattle. I'm going for a second opinion and will let you know the outcome.
Tony
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Unread 05-25-2013, 08:30 PM   #36
WieSeL
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Probably a chain guide. Just replaced one in a Nissan last week that was making a similar noise
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Unread 05-29-2013, 10:22 PM   #37
breckman99
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Join Date: Jul 2012
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I'm afraid that the original diagnosis is correct. After spending an extended period of time poking around with the stethoscope I can confirm that this rattle is coming from the timing case. Here is another video showing the rattle:


The first and most likely candidate for failure is the timing chain tensioner. I am going to order a new tensioner and see if this remedies the rattle. If it does, then I'll have to obtain the camshaft lock tools to measure chain stretch in case the additional free play in the chain has caused accelerated wear / stretch on the chain itself.

If the tensioner does not cure the rattle, then we are into the realm of cylinder head removal and replacement of the timing guide rails as well.

The link in the beginning of this thread seems to indicate that there were possible known oil passage restrictions on the OM642 which would cause failures on the hydraulic circuit pressurizing the tensioner. If this is the case, i hope the passage they speak of is within the tensioner assembly itself and not between the head and block.

I sure hope this all boils down to a defective tensioner. If I have to pull the cylinder heads on a 62K mi Mercedes diesel engine I am going to be extremely unhappy. I bought this vehicle with the intention of not performing any major service for an extended period of time.
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Unread 05-29-2013, 10:24 PM   #38
breckman99
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2007 WK 
 
Join Date: Jul 2012
Location: , CO
Posts: 58
Here are some procedures for R+R of the timing rails / tensioner / chain as well as method for chain stretch measurement:

COVER-TIMING CHAIN
REMOVAL
TIMING CHAIN COVER

Fig. 370: Insulated Engine Cover
Courtesy of CHRYSLER LLC

Disconnect negative battery cable. Refer to REMOVAL .
Remove the engine cover. See ENGINE COVER.
Remove the front engine cover bracket.
Raise and support the vehicle.
Drain the power steering into a suitable and appropriately marked container.
Remove the power steering hose between the pump and cooling fan.
Remove the power steering hose between the cooling fan and suspension.
Remove the lower cooling fan module retaining bolts.
Disconnect the cooling fan wiring harness connector.
Remove the power steering line between the retainer and cooling fan module.
Remove the front splash shield.

Fig. 371: Vibration Damper & Front Oil Pan Bolts
Courtesy of CHRYSLER LLC

1-VIBRATION DAMPER
2-OIL PAN BOLTS

Remove the front oil pan to timing cover bolts.
Lower the vehicle.
Remove the hoses at the power steering reservoir.
Remove the cooling fan module upper bolts and remove the fan assembly.
Remove the charge air outlet tube.

Fig. 372: Accessory Drive Belt Routing
Courtesy of CHRYSLER LLC

1-IDLER PULLEYS
2-DRIVE BELT TENSIONER
3-POWER STEERING PUMP
4-AIR CONDITIONING COMPRESSOR
5-VIBRATION DAMPER
6-GENERATOR
7-WATER PUMP

Remove the accessory drive belt.
Disconnect the charge air inlet hose at the EGR air control valve.
Remove the glow plug module.

Fig. 373: EGR Valve
Courtesy of CHRYSLER LLC

1-Item_1
2-Item _2

Remove the EGR air control valve.
Remove both accessory drive belt idler pulleys.
Remove the accessory drive belt tensioner.
Rotate the engine to TDC by the crankshaft bolt.

Fig. 374: Special Tool # XXXXX
Courtesy of CHRYSLER LLC

1-ENGINE BLOCK
2-SPECIAL TOOL #9102
3-FLEX PLATE

Raise and support the vehicle.
Remove the starter blank.
Install special tool 9102 crankshaft lock.
Lower the vehicle.

Fig. 375: Front Timing Cover & Crankshaft Seal
Courtesy of CHRYSLER LLC

1-TIMING CHAIN COVER
2-FRONT CRANKSHAFT SEAL

Remove the vibration damper and pulley.
Remove the front timing cover seal.
Remove the front timing cover bolts and cover.

INSTALLATION
TIMING CHAIN COVER

NOTE: Component mating surfaces must be clean and free of all oil residue.

Fig. 376: Front Timing Cover & Crankshaft Seal
Courtesy of CHRYSLER LLC

1-TIMING CHAIN COVER
2-FRONT CRANKSHAFT SEAL

Install the front crankshaft seal in the timing cover (1).
Install the timing cover (1). Tighten bolts to 9 N.m (7 ft. lbs.).
Raise and support the vehicle.

Fig. 377: Vibration Damper & Front Oil Pan Bolts
Courtesy of CHRYSLER LLC

1-VIBRATION DAMPER
2-OIL PAN BOLTS

Install the front oil pan bolts. Tighten bolts to 10 N.m (88 in. lbs.).
Lower the vehicle.

Fig. 378: Accessory Drive Belt Routing
Courtesy of CHRYSLER LLC

1-IDLER PULLEYS
2-DRIVE BELT TENSIONER
3-POWER STEERING PUMP
4-AIR CONDITIONING COMPRESSOR
5-VIBRATION DAMPER
6-GENERATOR
7-WATER PUMP

Install the vibration damper and pulley. Tighten bolt to 210 N.m (154 ft. lbs.), and then an additional 180°
Install the accessory drive belt tensioner. Tighten bolt to 58 N.m (43 ft. lbs.).
Install the idler pulleys. Tighten bolts to 28 N.m (20 ft. lbs.).
Install the accessory drive belt.

Fig. 379: EGR Valve
Courtesy of CHRYSLER LLC

1-Item_1
2-Item _2

Install the EGR air control valve assembly.
Install the glow plug module.
Install the charge air outlet tube.
Install the cooling fan module. Tighten upper bolts to 14 N.m (10 ft. lbs.).
Raise and support the vehicle.

Fig. 380: Special Tool # XXXXX
Courtesy of CHRYSLER LLC

1-ENGINE BLOCK
2-SPECIAL TOOL #9102
3-FLEX PLATE

Remove special tool 9102 crankshaft lock.
Install the starter blank.
Install the lower cooling fan module bolts. Tighten lower bolts to 14 N.m (10 ft. lbs.).
Install the power steering line between the retainer and cooling fan module.
Connect the cooling fan wiring harness connector.
Install the power steering hose between the cooling fan and suspension.
Install the power steering hose between the pump and cooling fan.
Install the front skid plate.
Lower the vehicle.
Install the hoses at the power steering reservoir.
Fill the power steering reservoir.

Fig. 381: Insulated Engine Cover
Courtesy of CHRYSLER LLC
Install the front engine cover bracket.
Install the engine cover.
Connect the negative battery cable.
Purge the air from the power steering system before starting by raising the vehicle and rotating the steering wheel back and forth 20 times.
Start the engine and follow the bleed procedure with the scan tool.
Turn engine off and inspect for leaks.

SPROCKETS-TIMING CHAIN AND
REMOVAL
TIMING CHAIN

Fig. 382: Timing Chain And Guides
Courtesy of CHRYSLER LLC

To check the timing chain for wear and stretch, remove the right-bank cylinder head cover and position the engine at TDC of cylinder number one Lock the camshafts with special tool 8929-Locking Pins. The timing marks on the camshaft gears must face each other. Rotate the engine in the direction of rotation only and do not turn back otherwise measurement errors can result. With the camshafts locked, check the position of the vibration damper. The chain stretch is measured by the number of crankshaft degrees past the TDC mark. The timing chain is OK when the belt pulley is at the marking at max. 11° after TDC with locked camshafts. Replace the timing chain has stretched beyond specifications.

Fig. 383: Timing Chain Routing
Courtesy of CHRYSLER LLC

Disconnect negative battery cable. Refer to REMOVAL .
Remove the right cylinder head cover. See REMOVAL.
Make sure the crankshaft is turned to the TDC. Verify TDC of the crankshaft by lining up the mark on the front cover with the mark on the crankshaft damper.
Make sure that the timing marks on the back of the camshafts are horizontal and pointing at each other.
Remove the timing chain tensioner.

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.

Fig. 384: Special Tool Components And Timing Chain
Courtesy of CHRYSLER LLC

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

Install special tool # XXXXX using two of the cylinder head cover bolts.
Assemble special tool #9312-1 using 9312-3 and 9312-4. Install insert #9312-13 and retain with screw provided.

CAUTION: Care must be taken not to drop the timing 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.

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.

Fig. 385: Preventing Chain From Falling
Courtesy of CHRYSLER LLC
Carefully turn the thrust pin #9312-13 of special tool #9312-1 clockwise while holding the handle until the rivet is pressed out and the chain is separated. Discard the loose link and plates.
Use a small screwdriver to prevent the timing chain from slipping into the engine.

NOTE: One whole timing chain link must be removed.

CAUTION: IT IS ESSENTIAL that the installation procedure for the timing chain is followed exactly. Failure to do so will result in severe engine damage.

TIMING CHAIN TENSIONING RAIL

Fig. 386: Left Lower Timing Chain Guide And Fastener
Courtesy of CHRYSLER LLC

1-LEFT LOWER TIMING CHAIN GUIDE
2-FASTENER

Disconnect negative battery cable.
Remove cylinder head. See REMOVAL.
Remove timing chain cover. See REMOVAL.

Fig. 387: Upper Timing Chain Guide Pin Extraction
Courtesy of CHRYSLER LLC

1-GUIDE PIN
2-SLIDE HAMMER
3-LOWER TIMING CHAIN GUIDE
4-UPPER TIMING CHAIN GUIDE

Remove the timing chain guide pin.
Remove the timing chain retaining bolt.
Remove the timing chain tensioner.

GUIDE-TIMING CHAIN-UPPER

NOTE: When servicing the timing chain guides, both the upper and the lower guide should be replaced in pairs.

Fig. 388: Timing Chain And Guides
Courtesy of CHRYSLER LLC

Disconnect negative battery cable. Refer to REMOVAL .
Remove the left cylinder head cover. See REMOVAL.
Remove the right cylinder head cover. See REMOVAL.
Remove the timing chain cover. See REMOVAL.

Fig. 389: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Remove the timing chain tensioner (3).

Fig. 390: Left Exhaust Camshaft Drive Gear Alignment Dowel
Courtesy of CHRYSLER LLC

1-LEFT INTAKE CAMSHAFT
2-LEFT EXHAUST CAMSHAFT DRIVE GEAR ALIGNMENT DOWEL
3-LEFT EXHAUST CAMSHAFT DRIVE GEAR
4-HIGH PRESSURE FUEL INJECTION PUMP

Rotate the engine and remove the right camshaft drive gear lower bolt.
Rotate the engine back to TDC and check the alignment marks at the balance shaft, camshaft gear and crankshaft gear.
Remove the remaining right camshaft drive gear retaining bolts.
Separate the right camshaft drive gear and chain from camshaft.
Remove the right camshaft drive gear.
Secure the chain so that there is slack at the timing chain guides but the chain remains on the crankshaft gear.

Fig. 391: Upper Timing Chain Guide Pin Extraction
Courtesy of CHRYSLER LLC

1-GUIDE PIN
2-SLIDE HAMMER
3-LOWER TIMING CHAIN GUIDE
4-UPPER TIMING CHAIN GUIDE

Cut a small section of tubing, with an inner diameter of the tube that is larger than the outer diameter of the timing chain guide pin, 25 mm (1 inch) in length.
Place the tube over the timing chain guide pin and thread a bolt into the timing chain guide pin in the right cylinder head. Tighten the bolt until the guide pin is removed from the cylinder head.

Fig. 392: Right Timing Chain Guides
Courtesy of CHRYSLER LLC

1-UPPER TIMING CHAIN GUIDE
2-LOWER TIMING CHAIN GUIDE

Remove the bolt for the left upper timing chain.
Remove the upper timing chain guide from the left cylinder head.
Remove the bolt for the right upper timing chain.
Remove the upper timing chain guide in the right cylinder head.

INSPECTION
TIMING CHAIN STRETCH PROCEDURE

Fig. 393: Timing Chain Routing
Courtesy of CHRYSLER LLC

Remove the left cylinder head cover. See REMOVAL.
Remove the right cylinder head cover. See REMOVAL.

Fig. 394: Retainer, Camshafts-9555
Courtesy of CHRYSLER LLC
Install the camshaft retainers.

Fig. 395: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Make sure that the timing chain cover is fully seated.

Fig. 396: #8929 Camshaft Locking Pin
Courtesy of CHRYSLER LLC
Rotate the crankshaft clockwise until the crankshaft is at TDC and the camshaft locking pins can be installed.
With the locking pins installed, turn the crankshaft clockwise until the timing chain is completely tight. If the marks on the crankshaft damper exceed 11 degrees, replace the timing chain.

INSTALLATION
GUIDE-TIMING CHAIN-UPPER

Fig. 397: Timing Chain And Guides
Courtesy of CHRYSLER LLC

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

Fig. 398: Right Timing Chain Guides
Courtesy of CHRYSLER LLC

1-UPPER TIMING CHAIN GUIDE
2-LOWER TIMING CHAIN GUIDE

Install the right side upper timing chain guide and bolt (1).
Install the upper timing chain guide pin in the right cylinder head.
Install the left side upper timing chain guide and bolt.
Install the upper timing chain guide pin in the left cylinder head.

Fig. 399: Left Exhaust Camshaft Drive Gear Alignment Dowel
Courtesy of CHRYSLER LLC

1-LEFT INTAKE CAMSHAFT
2-LEFT EXHAUST CAMSHAFT DRIVE GEAR ALIGNMENT DOWEL
3-LEFT EXHAUST CAMSHAFT DRIVE GEAR
4-HIGH PRESSURE FUEL INJECTION PUMP

Install the camshaft drive gear on the exhaust camshaft in the right cylinder head.
Install the upper two bolts into the camshaft drive gear and tighten to 18 N.m (159 lbs. in.).

Fig. 400: Camshaft Gear Alignment
Courtesy of CHRYSLER LLC

1-CAMSHAFT GEAR
2-CAMSHAFT GEAR ALIGNMENT MARKS
3-CAMSHAFT DRIVE GEAR DOWEL POSITION

Be sure that all of the timing marks are correctly aligned.
Rotate the engine and install the lower bolt into the camshaft drive gear. Tighten to 18 N.m (159 lbs. in.).

Fig. 401: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Install the timing chain tensioner and torque to 80 N.m (59 lbs. ft.)
Install the timing cover. See INSTALLATION.
Install oil pan bolts. Tighten M6 bolts to 9 N.m (80 lbs. in.) and M8 bolts to 20 N.m (15 lbs. ft.).
Reconnect negative battery cable. Refer to INSTALLATION .

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.

Start the engine, allow to warm, turn engine off and inspect for leaks. Care must be take to observe the fuel system warnings.

TIMING CHAIN TENSIONING RAIL

Fig. 402: Left Lower Timing Chain Guide And Fastener
Courtesy of CHRYSLER LLC

1-LEFT LOWER TIMING CHAIN GUIDE
2-FASTENER

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

Install tensioning rail on bearing pin
Install the timing chain tensioner retaining bolt. Tighten to 12 N.m (106 lbs. in.)
Install timing cover. See INSTALLATION.
Install oil pan and bolts. Tighten M6 bolts to 9 N.m (80 lbs. in.) and M8 bolts to 20 N.m (15 lbs. ft.).
Install cylinder head. See INSTALLATION.
Install the cylinder head covers. See INSTALLATION.
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.

Start the engine and inspect for leaks. Care must be taken to observe the fuel system warnings.

ADJUSTMENTS
TIMING CHAIN

Fig. 403: Preventing Chain From Falling
Courtesy of CHRYSLER LLC

CAUTION: IT IS ESSENTIAL that the installation procedure 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.

Use a small screwdriver to prevent the timing chain from slipping down into the engine.

Fig. 404: Timing Chain Master Link
Courtesy of CHRYSLER LLC

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

Connect new timing chain, oil hole side up and old timing chain with the assembly link.

Fig. 405: Master Link-Reverse Side
Courtesy of CHRYSLER LLC
Place the baking plate on the back side of the master link.

Fig. 406: Master Link Clip
Courtesy of CHRYSLER LLC
Place the master link clip on the master link.

Fig. 407: Master Link Clip Installed
Courtesy of CHRYSLER LLC

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: With the timing cover and special tools in place, the timing chain cannot jump time while being fed through the engine. As the engine is rotated the timing chain may appear to slip as the valve springs move the camshafts.

Fig. 408: Feeding The Chains Through
Courtesy of CHRYSLER LLC

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

Draw in new timing chain with the oil holes facing up, by rotating the crankshaft slowly in direction of rotation of engine.
Rotate the engine until the ends of the new timing chain meet and can be connected.

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

Remove assembly locking element, assembly outer plate and assembly link.
Insert new riveted link with the oil hole up, and new middle plate into ends of timing chain using the guide link to hold the middle plate in position.

Fig. 409: Inserting New Timing Chain Link
Courtesy of CHRYSLER LLC

1-GUIDE LINK
2-NEW LINK
3-SPECIAL TOOL #9312-1
4-TOOL INSERT #9312-7
5-TOOL INSERT #9312-10
6-THRUST PIN #9312-4

NOTE: When assembling riveting tool, piece #9312-7 is secured by a screw and #9312-10 can move loosely on thrust spindle

Assemble riveting tool by inserting pieces #9312-7 and #9312-10.

Fig. 410: Installing Assembly Inserts Into Riveting Tool
Courtesy of CHRYSLER LLC

1-SPECIAL TOOL #9312-1
2-SPECIAL TOOL #9312-7 and 9312-10

NOTE: Ensure that the riveted link and riveting tool are aligned.

Press in new riveted link as far as the stop.

Fig. 411: Pressing New Rivet Link
Courtesy of CHRYSLER LLC

1-SPECIAL TOOL #9312-1
2-GUIDE LINK
3-SPECIAL TOOL INSERT 9#312-7
4-SPECIAL TOOL INSERT #9312-10
5-THRUST SPINDLE #9312-4

Remove guide link and riveting tool to change inserts.
Install insert 9312-8a on riveting tool.

NOTE: The outer plate is held magnetically by riveting tool.

Insert new outer plate into the moving assembly insert.
Position riveting tool so that spacer webs of the guide are side by side.
Ensure that riveted link and outer plate are aligned.

NOTE: When turning spindle of riveting tool, be sure that pins of riveted link are inserted into holes of outer plate

Screw in spindle of riveting tool until firm resistance is felt.

Fig. 412: Outer Plate Installation
Courtesy of CHRYSLER LLC

1-SPECIAL TOOL #9312-1
2-THRUST SPINDLE #9312-4
3-TOOL INSERT #9312-8
4-TOOL INSERT #9312-6

Remove riveting tool.
Install moving assembly insert #9312-a11 to #9312-1.
Position riveting tool exactly over middle of pin.
Tighten riveting tool spindle to end of travel.
Repeat procedure for both riveting pins.

Fig. 413: Riveting Link Pins
Courtesy of CHRYSLER LLC

1-SPECIAL TOOL #9312-1
2-THRUST SPINDLE
3-RIVETING PROFILE
4-INSERT 9312-6

Inspect riveting, re-rivet if required.

Fig. 414: Inspecting Rivet
Courtesy of CHRYSLER LLC
Install cylinder head cover. See INSTALLATION.
Install engine cover. See ENGINE COVER.
Connect negative battery cable.
Start engine and inspect for leaks. Care must be taken to observe the fuel system warnings.

TENSIONER-TIMING CHAIN
DESCRIPTION

Fig. 415: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

The timing chain tensioner is located on the right cylinder head. The tensioner is hydraulically operated with the adjusting portion riding on the right timing chain guide. Hydraulic support for the tensioner is supplied by forward oil passages in the right cylinder head.
REMOVAL
TIMING CHAIN TENSIONER

Fig. 416: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Disconnect negative battery cable. Refer to REMOVAL .
Open hood.
Remove engine cover. See ENGINE COVER.
Remove the engine intake air duct.
Remove air cleaner housing. Refer to REMOVAL .
Remove the cable strap from the engine wiring harness.
Remove the timing chain tensioner.

INSTALLATION
TIMING CHAIN TENSIONER

Fig. 417: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

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

Install timing chain tensioner with new gasket. Tighten to 80 N.m (59 lbs. ft.).
Install cable strap on the engine wiring harness.
Install air cleaner housing.
Install intake air duct.
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.

Start the engine and inspect for leaks.

BALANCE SHAFT
REMOVAL

Fig. 418: Timing Chain Routing
Courtesy of CHRYSLER LLC

Disconnect the battery. Refer to INSTALLATION .
Remove the transmission and torque converter. Refer to INSTALLATION .
Position piston 1 to TDC.

NOTE: To set piston #1 to Top Dead Center (TDC), Rotate the engine at the crankshaft in the running direction. The markings on the camshaft sprockets must be positioned opposite each other. The markings on the camshaft sprockets must be aligned with the cylinder head and lie on the left side. The TDC marking on the vibration damper must be aligned with the stay on the timing case cover.

Remove the timing chain cover. See REMOVAL.

Fig. 419: Balance Shaft Rear Cover
Courtesy of CHRYSLER LLC
Remove the rear balance shaft cover.

Fig. 420: Balance Shaft Alignment - Rear
Courtesy of CHRYSLER LLC
Install a 8.5 mm diameter drill bit (2) into the balance shaft stop.

Fig. 421: Balance Shaft Alignment - Front
Courtesy of CHRYSLER LLC
Make sure that the notch in the balance shaft front counterweight is at the highest point of the weight. If the balance shaft is aligned correctly, remove the drill bit.
Remove the balance shaft hold down bolt (4).

Fig. 422: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Remove the timing chain tensioner.
Remove the bolt from the front of the balance shaft.
Remove the balance shaft.

INSTALLATION

Fig. 423: Balance Shaft Alignment Front
Courtesy of CHRYSLER LLC

Install the balance shaft.
Align the balance shaft so that the notch in the counterweight is facing directly up.

Fig. 424: Timing Chain Tensioner
Courtesy of CHRYSLER LLC

1-ENGINE OIL CAP
2-OIL LEVEL INDICATOR
3-TIMING CHAIN TENSIONER
4-OIL SEPARATOR ASSEMBLY
5-CAMSHAFT POSITION SENSOR

Install the timing chain tensioner. Torque to 80 N.m (59 ft. lbs.).
Be sure that the camshafts and crankshaft are all set to their correct timing positions.

Fig. 425: Balance Shaft Alignment Front
Courtesy of CHRYSLER LLC
Install the balance shaft bolt (4). Torque bolt to 35 N.m (309 in. lbs.).

Fig. 426: Balance Shaft Rear Cover
Courtesy of CHRYSLER LLC
Install the bolt in the rear of the balance shaft 20 N.m (177 in. lbs.) and then rotate an additional 90°.
Install the rear balance shaft cover. Torque bolts to 8 N.m (71.8 in. lbs.).
Install the timing chain cover. See INSTALLATION.
Install the torque converter and transmission. Refer to INSTALLATION .
Connect the battery. Refer to INSTALLATION .
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Unread 05-29-2013, 11:23 PM   #39
tleeming
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breckman99 Thanks for the posts...I'm sure your diagnosis is right. I listened to mine with a stethoscope too and the sound is definitely coming from the drivers side timing cover area. I think replacing the timing chain tensioner is a good idea. Suzieque already suggested that.
The list you provided of the work required is huge...no wonder the cost is high. Can you keep us posted and I will too.
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Unread 05-31-2013, 09:47 PM   #40
breckman99
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I went down to the Mercedes dealership to pick up a new chain tensioner yesterday. I ordered part number 642 050 03 11 for around $117, should be here Monday.

On my way out of the dealership the electronic throttle warning indicator begin to flash along with the limitation of power associated with a limp home mode. Swirl motor. Not a good week for this CRD.


Once I get the tensioner I'll report back. I'd like find a cutaway displaying the oil port to the tensioner as it would be nice to run a stiff wire through it to ensure it is not obstructed.
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Unread 06-01-2013, 11:23 AM   #41
suzieque
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Quote:
Originally Posted by breckman99 View Post
I went down to the Mercedes dealership to pick up a new chain tensioner yesterday. I ordered part number 642 050 03 11 for around $117, should be here Monday.

On my way out of the dealership the electronic throttle warning indicator begin to flash along with the limitation of power associated with a limp home mode. Swirl motor. Not a good week for this CRD.


Once I get the tensioner I'll report back. I'd like find a cutaway displaying the oil port to the tensioner as it would be nice to run a stiff wire through it to ensure it is not obstructed.
It would be good if you could post some pictures of the tear down.
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2008 WK "S" Limited bright metallic silver exterior, light graystone interior, 5 speed W5J400 transmission, June 18/2008 build, C213RE rear differential with 3.73 axle ratio, C200FE front differential with 3.73 axle ratio, 245/60R18 Goodyear Fortera tires (stock summer tires), NV245 transfer case, GT2056V turbo, 3.0L CRD (OM642.980)
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Unread 06-01-2013, 11:47 AM   #42
breckman99
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Quote:
Originally Posted by suzieque View Post
It would be good if you could post some pictures of the tear down.
suzieque,

I'll try to get some good pictures of the tensioner and its hole. It might be a bear as I can't even see it when looking down there with all the airbox etc in the way. I sure hope its a nice simple operation, and I can actually get something into the oil port. As an alternative I was thinking of holding the tensioner rail with a rod and running the engine for a moment to see if there is oil flow from the tensioner port. I suppose I will see how it works when I get it apart. I still have not found a nice picture of the oil passage feeding the tensioner anywhere...
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Unread 06-01-2013, 12:05 PM   #43
breckman99
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Here is the best image I could find, and I am guessing that the oil passage is where the red line is.

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Unread 06-01-2013, 12:17 PM   #44
tleeming
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[QUOTE=breckman99;15505262]

On my way out of the dealership the electronic throttle warning indicator begin to flash along with the limitation of power associated with a limp home mode. Swirl motor. Not a good week for this CRD.

Not good....been there and done that twice. Make sure the seal on the air intake to the turbo is replaced. I installed a Provent CV filter too...no more problems.
The first limp mode occurred in Mexico while towing a 24ft RV. I had to tow it in limp mode 600 kms to our RV Park. After dumping the RV at the park I drove 1600 km to Tucson to get the swirl motor fixed. On the way back from Mexico in Tucson it went again!
I did the elephant mod in Tucson then the Provent installation back in BC Canada.
I wish I knew about the resistor across the plug terminals then!
I hope this new tensioner solves our problem
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Unread 06-01-2013, 12:34 PM   #45
tleeming
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Just priced the chain tensioner at BC Canada dealers
Jeep $246.00
Merc. $ 205.33
The lowest price I found in the USA was $66!! http://www.jeep4x4center.com/timing-...8017937aa.html
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