Remove/install camshaft

AR05.20-G-6292DD

Remove/install camshaft

21.08.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Modification notes

07.03.2019

Work procedure completely revised

Shown on engine 900.9

1

Cylinder head

4

Pilot bushing

2

Push rods

11

Camshaft position sensor

3

Crankcase

3

Crankcase

8

Camshaft bearing

5

Camshaft

9

Camshaft sprocket

6

Centering drift

10

Valve tappet

7

Crankshaft gear

A

Markings

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A



Remove

1

Attach engine to the engine assembly stand.

 Assembly stand

*000588013100

2

Remove timing case.

AR01.60-G-8200DD

3

Remove fuel pump.

Only with diesel engine

AR47.20-G-5710DD

4

Remove engine control/PLN unit pumps.

Only with diesel engine

AR07.15-G-8950DD

5

Remove rocker arm assembly.

AR05.00-G-5521DD

6

Remove push rods (2) from cylinder head (1).

7

Pull camshaft position sensor (11) out of crankcase (3).

 Do not disconnect electrical connector.

8

Rotate engine in engine assembly stand.

 Rotate engine by about 180° so that valve tappets (10) detach from camshaft (5).

9

Attach pilot bushing (4) to camshaft (5).

 Assembly stand

*000588013100

 Guide sleeve

*904589021400

10

Carefully pull camshaft (5) with camshaft sprocket (9) and pilot bushing (4) out of crankcase (3).


Carefully pull out camshaft (5).
The camshaft bearing (8) will be damaged otherwise.

11

Mark valve tappets (10) relative to crankcase (3) and remove from crankcase (3).



Check

12

Check camshaft (5) by means of a visual inspection for damage or wear.

If wear or damage is found,



Replace camshaft (5).

13

Check treads of camshaft bearing (8) in crankcase (3) by means of a visual inspection for wear, score marks or scratches.

If wear or damage is found,



Replace crankcase (3).

14

Check valve tappets (10) by means of a visual inspection for damage or wear.

If wear or damage is found,



Replace valve tappets (10) involved.

15

Check push rods (2) for damage or wear on the socket or the ball head

If wear or damage is found,



Replace affected push rods (2).



Install

16

Coat valve tappets (10) with engine oil and insert in crankcase (3).

 Observe identification of valve tappets (10) relative to the crankcase (3).

17

Introduce camshaft (5) with pilot bushing (4) carefully in crankcase (3) and align camshaft sprocket (9) to crankshaft gear (7).


Introduce camshaft (5) carefully.
The camshaft bearing (8) will be damaged otherwise.

 Markings (A) on camshaft sprocket (9) and crankshaft gear (7) must face each other.

If markings (A) do not face each other,



Screw centering drift (6) into the crankshaft and turn crankshaft using a suitable lever.

 Guide sleeve

*904589021400

 Alignment punch

*904589026300

18

Remove pilot bushing (4) from camshaft (5).

19

Rotate engine in engine assembly stand.

 Rotate engine by about 180° so that valve tappets (10) touch the camshaft (5).

20

Check bushing for camshaft position sensor (11).

If the bushing is damaged:



Replace bush.

21

Push in camshaft position sensor (11) all the way into crankcase (3).

22

Coat push rod (2) sockets with engine oil and insert push rods (2) into cylinder head (1).

 Ensure correct seating of the push rods (2) in the valve tappets (10).

23

Install rocker arm assembly.

24

Check valve clearance.



AP05.30-G-0560DD

If necessary,



Set valve clearance.

25

Install engine control/PLN unit pump.

Only with diesel engine

AR07.15-G-8950DD

26

Install fuel pump.

Only with diesel engine

AR47.20-G-5710DD

27

Install timing case.

AR01.60-G-8200DD

28

Remove engine from engine assembly stand.

 Assembly stand

*000588013100

29

Fill oil circuit.

AR18.00-G-1600DD