I just torqued down a rebuilt cylinder head and I'm trying to install the camshaft, timing gear, and timing chain but I can't seem to slip the chain around the gear. It seems too short! I don't have the tensioner installed either. Do I have to break the chain or should I be able to slip it over the timing gear and then install the tensioner?

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1991 190e 2.6 190,000mi

it should go back on fairly easy, try moving the crank left and right, the chain may be slightly knked, be sure that when you are moving te crank to hold tension on the chain, and not to turn it to much or with much forse so you don't damage valves

What do you mean by moving the crank left and right? I've rotated the engine a couple of times using a 27mm socket while holding tension on the chain thinking their were kinks but the chain never "released" any more slack.

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1991 190e 2.6 190,000mi

if there were kinks that would have done it, did you do it with the head on or off?

when I mdid mine I took bailing wire and kept the chain and gear together, then slipped it back on cam, and yes you can get it kinked, you did remove the tensioner right, have someone hold up the chain and rotate athe crank just a little back and forth and pull up on chain, the last is put the pin back in the head for the rail

After 3 days of troubleshooting, I still can't figure out why the timing chain is too short to go around the camgear and then slip onto the camshaft.

1. There are no kinks in the chain. The chain is smooth when I rotate the crank in both directions while hodling tension on the chain.
2. tensioner is not installed
3. the chain is the correct length, 96 links

I'm thinking of cutting the chain, pulling it out, and then rerouting a new chain. Is that possible to do? I'm open to other ideas or if someone in the SanDiego area is willing to come to the rescue, I'd greatly appreciate it.

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1991 190e 2.6 190,000mi

i am in san diego, when can i come over?, have you tried putting the chain on the gear then trying to put it on the cam?

Ray, I tried putting the chain around the gear and then trying to put the gear over the cam. I've also tried putting the gear on the cam and then trying to put the chain around the gear. Both unsuccessful. Any time today is great! I'm watching the Chargers upset the Colts. I'll email you

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1991 190e 2.6 190,000mi

i will be heading up that way later today, i will give you a call when i am near you

Problem solved... If you've ever had the timing chain cover removed, you've seen several structural support "pegs" on the backside of the cover which are part of the cast aluminum piece. When I re-installed the cover, one of the "pegs" got between the chain and the crankgear. It all went back together smooth and the timing chain was also smooth as I rotated it. However, the end result was that the timing chain was several inches shorter when I was trying to put the chain over the camgear. I had to remove the timing chain cover again to discover what I had done wrong. Thanks to Carson356 for helping me diagnose the problem as well as install & crimp a new timing chain. If anyone wants pictures of the "pegs", back of the timing cover, or the front end of the engine with the timing cover off I'd be happy to post a picture.

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1991 190e 2.6 190,000mi