Remove/install rocker arm housing

AR05.00-W-5551MD

Remove/install rocker arm housing

17.11.15

Engine

936.9 in model 963, 964

Modification notes

19.3.13

Remove/install compressor resonator, added.

Operation step 4, 44

AR13.10-W-5840MD

1

Wiring harness

2

Bracket

3

Heat shield

Y635

Camshaft adjuster solenoid

4

Bracket (for code B3H (Secondary water retarder))

7

Intake rocker arm assembly

B601

Camshaft position sensor

5

Coolant pipe (for code B3H (Secondary water retarder))

8

Exhaust rocker arm assembly

6

Clamps

9

Bracket

7

Intake rocker arm assembly

10

Screw/bolts

13

Camshaft

8

Exhaust rocker arm assembly

11

Rocker arm housing

11

Rocker arm housing

12

Camshaft bearing halves

14

Seal

Pfeil

Range

11

Rocker arm housing

15

Rocker arm assembly

16

Pin

Pfeile

Hole

 Danger !

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger !

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A



Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Notes on tilting the cab

AH60.80-N-0003-01A



Remove

1

Tilt cab

2

Remove soundproofing

3

Drain coolant at engine radiator

AR20.00-W-1142M

4

Remove compressor resonator

AR13.10-W-5840MD

5

Disconnect electrical connection from camshaft adjuster solenoid (Y635)

6

Expose wiring harness (1) on rocker arm housing (11)

7

Remove camshaft adjuster solenoid (Y635)

 Turn camshaft adjuster solenoid (Y635) clockwise and pull out.

8

Remove bracket (2)

9

Remove bracket (4) for coolant pipe (5)

Only on vehicles with code B3H (Secondary Water Retarder).

10

Remove heat shield (3)

11

Remove exhaust gas recirculation cooler

AR14.20-W-7665MD

12

Remove bracket (9)

13

Remove cylinder head cover

AR01.20-W-5014MD

14

Remove injectors wiring harness

AR07.16-W-1008MD

15

Attach turning device for engine

AR03.30-W-1600-03MD

 Bolt, turning device to flywheel housing

*BA01.60-N-1002-01O

 Turning device

*904589046300

16

Place engine at ignition TDC on cylinder 1 and lock

AR05.10-W-7620-03MD

 Turning device

*904589046300

 Drift

*936589001500

 Template

*936589002300

17

Remove screw/bolts (10) for inlet rocker arm assembly (7), the exhaust rocker arm assembly (8) and the rocker arm housing (11)

AR05.00-W-5551-01MD

 Observe loosening procedure for rocker arm housing (11).

18

Remove bearing cap for inlet rocker arm assembly (7) and the exhaust rocker arm assembly (8)

 Mark installation position of bearing cap.

19

Remove intake rocker arm assembly (7) and exhaust rocker arm assembly (8)

20

Remove rocker arm housing (11) from cylinder head

 Note the camshaft bearing halves (12) in the rocker arm housing (11).

21

Remove camshafts (13)

AR05.20-W-6992MD

 The camshafts (13) must be removed to check the camshaft bearing halves (12) in the cylinder head.

22

Check camshaft bearing halves (12) for wear and damage

 Check camshaft bearing halves (12) for wear, score marks or scratches.
If there is a strongly visible or clearly perceptible wear as well as score marks or scratches then the camshaft bearing shells (12) must be replaced.

23

Check camshafts (13) for wear and damage

 Check contact surfaces for camshafts (13) for wear, score marks or scratches.
If there is a strongly visible or clearly perceptible wear as well as score marks or scratches then the camshafts (13) must be replaced.



Install

24

Clean sealing surfaces on the cylinder head and rocker arm housing (11)

25

Insert new seal (14) on rocker arm housing (11)

 Fasten seal (14) in the area (arrow) of the camshaft adjuster solenoids (Y635) with sealant in order to avoid falling out of the seal (14) during installation of the rocker arm housing (11).

26

Place rocker arm housing (11) on cylinder head

 Check whether seal (14) is seated correctly.
Check position of the camshaft sprockets; lift rocker arm housing (11) somewhat and turn the camshafts (13) appropriately.

27

Insert inlet rocker arm assembly (7) and exhaust rocker arm assembly (8) in the rocker arm housing (11)

 The drifts (16) on the rocker arm assemblies (15) must sit in the bores (arrows) of the rocker arm housing (11).

28

Insert bearing cap for inlet rocker arm assembly (7) and the exhaust rocker arm assembly (8)

 Note the applied markings during removal.

29

Insert screw/bolts (10) for rocker arm housing (11) and tighten down

AR05.00-W-5551-02MD

 Observe tightening procedure for rocker arm housing (11).

 Bolt, spring steel sheet for solenoid on camshaft positioner to rocker arm frame

*BA05.00-N-1003-01N

 Bolt, bracket for rocker arm assembly to cylinder head

*BA05.00-N-1002-01N

 Screw/bolt, rocker arm frame to cylinder head

*BA05.00-N-1004-01N

30

Install bracket (9)

 Bracket, exhaust gas recirculation cooler clamps to cylinder head

*BA14.20-N-1011-01J

31

Install exhaust gas recirculation cooler

AR14.20-W-7665MD

 Check clamps (6) for exhaust gas recirculation cooler for damage; replace if necessary.

32

Install heat shield (3)

33

Install bracket (4) for coolant pipe (5)

Only on vehicles with code B3H (Secondary Water Retarder).

 Bolt, retarder coolant pipe bracket on retarder coolant pipe

*BA43.30-N-1019-01F

 Bolt, bracket for retarder coolant pipe to rocker arm frame

*BA43.30-N-1018-01F

34

Install bracket (2)

 Coolant line bracket to rocker arm frame

*BA14.20-N-1012-01J

35

Install camshaft adjuster solenoid (Y635)

36

Fasten wiring harness (1) to rocker arm housing (11)

37

Connect electrical connection to camshaft adjuster solenoid (Y635)

38

Remove turning device at flywheel housing

AR03.30-W-1600-03MD

 Bolt, TDC inspection hole cap to flywheel housing

*BA01.60-N-1001-01O

 Turning device

*904589046300

39

Remove drift from flywheel housing

 Drift

*936589001500

40

Install crankshaft position sensor and tighten down screw/bolt

 Replace sealing ring.

 Bolt, crankshaft position sensor to flywheel housing

*BA07.04-N-1001-01I

41

Remove template on rocker arm housing (11)

 Template

*936589002300

42

Install injectors wiring harness

AR07.16-W-1008MD

43

Install cylinder head cover

AR01.20-W-5014MD

44

Install compressor resonator

AR13.10-W-5840MD

45

Pour in coolant

AR20.00-W-1142M

46

Perform an engine test run, stop engine and check in the area of the cylinder head cover and the rocker arm housing (11) for leaktightness

 Visual inspection.

47

Install soundproofing

48

Tilt back cab

 Timing case, flywheel housing

Number

Designation

Engine 936.9

BA01.60-N-1001-01O

Bolt, TDC inspection hole cap to flywheel housing

Nm

30

 Timing case, flywheel housing

Number

Designation

Engine 936.9

BA01.60-N-1002-01O

Bolt, turning device to flywheel housing

Nm

30

 Engine timing - general

Number

Designation

Engine 936.9

BA05.00-N-1002-01N

Bolt, bracket for rocker arm assembly to cylinder head

Nm

25

 Engine timing - general

Number

Designation

Engine 936.9

BA05.00-N-1003-01N

Bolt, spring steel sheet for solenoid on camshaft positioner to rocker arm frame

Nm

10

 Engine timing - general

Number

Designation

Engine 936.9

BA05.00-N-1004-01N

Screw/bolt, rocker arm frame to cylinder head

Nm

25

 Sensors, transmitters

Number

Designation

Engine 936.9

BA07.04-N-1001-01I

Bolt, crankshaft position sensor to flywheel housing

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 936.9

BA14.20-N-1011-01J

Bracket, exhaust gas recirculation cooler clamps to cylinder head

Nm

25

 Exhaust gas recirculation

Number

Designation

Engine 936.9

BA14.20-N-1012-01J

Coolant line bracket to rocker arm frame

Nm

25

 Retarder

Number

Designation

MODEL 963, 964 with CODE B3H (Secondary water retarder)

BA43.30-N-1018-01F

Bolt, bracket for retarder coolant pipe to rocker arm frame

Nm

25

 Retarder

Number

Designation

MODEL 963, 964 with CODE B3H (Secondary water retarder)

BA43.30-N-1019-01F

Bolt, retarder coolant pipe bracket on retarder coolant pipe

Nm

25