Remove/install camshafts

AR05.20-W-6992MD

Remove/install camshafts

12.12.2014

ENGINE

936.9 in MODEL 963, 964

Modification notes

03.12.2014

Damage to property reference to removal/installation for exhaust camshaft; inserted.

Operation steps 7 and 11

1

Intake camshaft

3

Rocker arm frame

7

Template

2

Exhaust camshaft

6

Gear

8

Control plunger

3

Rocker arm frame

4

Camshaft bearing halves

5

Cylinder head

 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

Remove cylinder head cover

AR01.20-W-5014MD

4

Attach turning device to the flywheel housing

AR03.30-W-1600-03MD

 Bolt, turning device to flywheel housing

*BA01.60-N-1002-01O

 Turning device

*904589046300

5

Place engine at ignition TDC on cylinder 1 and lock

AR05.10-W-7620-03MD

 The ignition TDC setting or catch must not be altered during the removal/installation of the intake camshaft (1) or exhaust camshaft (2). Perform operation steps again if necessary.

 Drift

*936589001500

 Template

*936589002300

6

Remove rocker arm frame (3)

AR05.00-W-5551MD

7

Remove intake camshaft (1) or exhaust camshaft (2)


During removal of the exhaust camshaft (2), make sure that the control plunger (8) is not damaged.
The exhaust camshaft (2) must be replaced otherwise.



Check

8

Check camshaft bearing shells (4) on cylinder head (5) and in rocker arm frame (3) for wear and damage

 Check camshaft bearing halves (4) by means of a visual inspection 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 halves (4) must be replaced.

9

Check intake camshaft (1) or exhaust camshaft (2) for wear and damage

 Check contact surfaces on intake camshaft (1) or exhaust camshaft (2) by means of a visual inspection for wear, score marks or scratches.
In the case of strongly visible or significantly perceptible wear as well as for score marks or scratches, the intake camshaft (1) or exhaust camshaft (2) must be replaced.



Install

10

Install camshaft bearing halves (4) on cylinder head (5)

Only if new camshaft bearing halves (4) are replaced.

 Observe different bearing widths and location of components of the oil holes for installation of the camshaft bearing halves (4).

11

Install intake camshaft (1) or exhaust camshaft (2)


During installation of the exhaust camshaft (2), make sure that the control plunger (8) is not damaged.
The exhaust camshaft (2) must be replaced otherwise.

 The bores on the gear (6) for intake camshaft (1) and exhaust camshaft (2) must match with the pins "" on the  template (7).
Lubricate intake camshaft (1) or exhaust camshaft (2) and the bearing shells (4) with engine oil.

 Template

*936589002300

12

Install camshaft bearing halves (4) on rocker arm frame (3)

Only if new camshaft bearing halves (4) are replaced.

 Observe different bearing widths and location of components of the oil holes for installation of the camshaft bearing halves (4).

13

Install rocker arm frame (3)

AR05.00-W-5551MD

14

Check valve clearance, adjust if necessary



AP05.30-W-0560MD

15

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

16

Pull out drift to lock the flywheel and install crankshaft position sensor

 Replace sealing ring.

 Bolt, crankshaft position sensor to flywheel housing

*BA07.04-N-1001-01I

17

Remove template (7)

18

Install cylinder head cover

AR01.20-W-5014MD

19

Install soundproofing

20

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

21

Check area of cylinder head cover and the rocker arm frame (3) for leaktightness and stop engine

 Visual inspection.

22

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

 Sensors, transmitters

Number

Designation

ENGINE 936.9

BA07.04-N-1001-01I

Bolt, crankshaft position sensor to flywheel housing

Nm

10