Remove/install camshafts

AR05.20-W-6992H

Remove/install camshafts

14.12.2018

Engine

470.9, 471.9, 473.9 in model 963, 964

Modification notes

31.05.2016

Work procedure completely revised.

Shown on engine 471.9

1

Camshaft bearing bridges

2

Camshaft housing

3

Intake camshaft

4

Exhaust camshaft

5

Gearwheels

6

Template

 Warning

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 it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Remove

1

Tilt cab

2

Remove soundproofing

3

Remove cylinder head cover

ENGINE 470.9

AR01.20-W-5014HB

Engine 471.9

AR01.20-W-5014HA

ENGINE 473.9

AR01.20-W-5014V

4.1

Remove intermediate frame under cylinder head cover

Engine 470.9 up to engine end number 222433, 471.9 up to engine end number 124618

AR01.20-W-5016H

4.2

Remove wiring harness of fuel injectors

Engine 470.9 as of engine end number 222434, 471.9 as of engine end number 124619, engine 473.9

AR07.16-W-1008H

5

Attach turning device to timing case

AR03.30-W-1600-03H

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

6

Position engine at ignition TDC on cylinder 1 and lock in place



Gearwheel drive modified

BT05.10-W-0002-01A

Up to engine end number 206646

AR05.10-W-7620-03H

From engine end number 206647

AR05.10-W-7620-03HA

 The ignition TDC setting or locking must not be altered during removal/installation of the intake camshaft (3) or exhaust camshaft (4).

 Drift

*470589001500

 Template

*470589032300

 Template

*470589062300

 Turning device

*904589046300

7

Remove rocker arm assembly

Intake rocker arm assembly

AR05.00-W-5521HA

Exhaust rocker arm assembly

AR05.00-W-5521HB

8

Mark installation location of the camshaft bearing bridges (1)

9

First loosen screw/bolts for the camshaft bearing bridges (1) in reverse order of the tightening procedure and then remove

Tightening procedure

AR05.20-W-6992-01H

10

Remove camshaft bearing bridges (1)

11

Remove intake camshaft (3) or exhaust camshaft (4)



Check

12

Check camshaft case (2) and camshaft bearing bridges (1) by means of visual inspection for wear, score marks or scratches

In the case of clearly recognizable wear as well as score marks or scratches



Replace camshaft case (2) with the camshaft bearing bridges (1).

13

Check contact surfaces on intake camshaft (3) or exhaust camshaft (4) by means of a visual inspection for wear, score marks or scratches

In the case of clearly recognizable wear as well as score marks or scratches



Replace intake camshaft (3) and/or exhaust camshaft (4).



Install

14

Install intake camshaft (3) or exhaust camshaft (4)


Lubricate intake camshaft (3) or exhaust camshaft (4) with engine oil.
Damage to the intake camshaft (3) or exhaust camshaft (4) can occur otherwise.

 The markings on the gears (5) must match with the markings on the  template (6).
Select markings on the  template (6) according to the displaced volume variants.

 Template

*470589032300

 Template

*470589062300

15

Install camshaft bearing bridges (1)

 Observe the installation position of the camshaft bearing bridges (1). The front and rear camshaft bearing bridge (1) is marked with "Front" or "Rear". Note the applied markings on the usual camshaft bearing bridges (1).

16

Tighten screw/bolts for camshaft bearing bridges (1) according to the tightening procedure

Tightening procedure

AR05.20-W-6992-01H

 Bolt, camshaft case with rocker arm bracket to cylinder head

*BA05.20-N-1001-04A

17

Install rocker arm assembly

Intake rocker arm assembly

AR05.00-W-5521HA

Exhaust rocker arm assembly

AR05.00-W-5521HB

18

Remove cranking device on timing case

AR03.30-W-1600-03H

 Bracket for front axle travel sensor to crescent-shaped crossmember

*BA32.30-N-1005-04B

 Screw/bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01N

19

Pull out drift on timing case

 Drift

*470589001500

20

Install crankshaft position sensor with the new sealing ring and tighten screw/bolt

 Bolt, crankshaft position sensor to timing case

*BA07.04-N-1001-01H

21

Remove template (6)

22.1

Install intermediate frame under cylinder head cover.

Engine 470.9 up to engine end number 222433, 471.9 up to engine end number 124618

AR01.20-W-5016H

22.2

Install wiring harness for fuel injectors

Engine 470.9 as of engine end number 222434, 471.9 as of engine end number 124619, engine 473.9

AR07.16-W-1008H

23

Install cylinder head cover

ENGINE 470.9

AR01.20-W-5014HB

Engine 471.9

AR01.20-W-5014HA

ENGINE 473.9

AR01.20-W-5014V

24

Install soundproofing

25

Tilt back cab

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1001-01N

Screw/bolt, cap of TDC inspection hole to timing case

Nm

30

30

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1002-01N

Bolt, turning device to timing case

Nm

30

30

 Camshaft case

Number

Designation

Engine 470.9, 471.9, 473.9

BA05.20-N-1001-04A

Bolt, camshaft case with rocker arm bracket to cylinder head

M8

Nm

25

M10

Stage 1

Nm

20

Stage 2

Nm

50

 Sensors

Number

Designation

Engine 470.9, 471.9, 473.9

BA07.04-N-1001-01H

Bolt, crankshaft position sensor to timing case

Nm

10

 Level control

Number

Designation

Model 963, 964

BA32.30-N-1005-04B

Bracket for front axle travel sensor to crescent-shaped crossmember

M10

Nm

50