guys,
i did do a search before posting this seemingly endless topic, but didnt find my answer. i am in the middle of an entire rebuild of my 77 240d engine. i have installed the new chain with no problems but am befuddled as to crimping it into place. my chain kit included: chain, conecting link, silver rear cap, and a black metal cap just like the silver one only the link holes in it are slightly smaller therefore not allowing it to be slipped on the link easily. my question: is this black metal cap to be snapped atop the silver one once it is on the conecting link in order to hold it in place? (at times like these i really wish i had illustration capabilities....) or, am i to disreguard the black link cap, and mearly use the silver one (which slipps on very easily) and smash the conecting link splines over the silver cap? if this method is to be used, can i crimp the splines without the use of a crimping tool? how is this done? thanks guys
william gum

The MB shop manual indicates amoung the required tools for this job a chain crimper.

To William Gumm,

There are dozens of posts in the archives on OM617 timing chain replacement, give them a look. The silver rear cap is the temporary one meant to hang on while the new chain is dragged around the engine while attached to the old chain. The black cover plate is the permanent one that must be crimped on with the proper crimping tool. I would not mash the rivets and expect to run the car another 200 k miles without problems. The tool is very specific and is referenced in the MB manual, all the way to the detail of how much torque you apply to the pin (actually a stout bolt) to apply crimping pressure. I used the factory tool on mine and it came out looking like the rest of the chain.

Point being, the tool is required for crimp on chains. I've heard of replacement chains being sold for these cars that have slip on "master links" that work well also, but you don't have that type of chain. Check with any of the usual on-line merchants and I'm sure one of them (or all) have the tool available for rental. If time is short, check your local indie or dealer and try to beg them to let you use their tool for an afternoon.

Good luck, it's really not too difficult once you get the crimping tool.