Remove/install camshafts

AR05.20-D-6992NB

Remove/install camshafts

04.02.2019

Engine

647.981 in model 903.61/66/67, 904.61/66

with code ZU7 (National version for Canada)

Engine

647.981 in model 903.61/66/67, 904.61/66

with code ZU8 (National version for USA)

Engine

647.981 in model 903.61/66/67, 904.61/66

with code ZU9 (National version for Mexico)

1

Intake camshaft

4

Chain tensioner

B

Markings

2

Exhaust camshaft

5

Front cover

C

Locking bore

3

Retaining pin

A

TDC marking

1

Intake camshaft

2

Exhaust camshaft

6

Bolts

7

Dowel pin

8

Camshaft timing gear

9

Screw

10

Camshaft bearing cap



Remove

1

Remove cylinder head cover

AR01.20-D-5014NB

2

Position piston of cylinder 1 to ignition TDC

 Turn engine clockwise at crankshaft to TDC marking (A). Do not crank engine backwards or at intake camshaft (1) and exhaust camshaft (2).
Cams of intake camshaft (1) and exhaust camshaft (2) of cylinder 1 must point upwards.

3

Lock intake camshaft (1)

 Insert retaining pin (3) through first camshaft bearing cap into locking hole (C) of intake camshaft (1).
Markings (B) in camshaft sprockets of intake camshaft (1) and exhaust camshaft (2) must face each other.

 Retaining pins

*111589031500

4

Remove front cover (5) at cylinder head

AR01.30-D-5700NB

5

Remove camshaft timing gear (8) at exhaust camshaft (2) and remove with mounted timing chain

 Counterhold exhaust camshaft (2) if necessary with open end wrench.

6

Remove camshaft bearing cap (10)

AR05.20-D-6992-04NA

Topical note

Marking on camshaft bearing caps

Motor 647.981

AH05.20-P-6992-04HE

7

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



Install

8

Insert intake camshaft (1) and exhaust camshaft (2)

 Oil valve clearance compensating elements and camshaft bearing points, align intake camshaft (1) and exhaust camshaft (2) at axial bearing (arrows b).
Mount intake camshaft (1) and exhaust camshaft (2) so that both markings (B) in camshaft sprockets of intake camshaft (1) and exhaust camshaft (2) face each other. Markings of intake camshaft (1), exhaust camshaft (2) and camshaft bearing cap (arrows a) must be alignment.
Observe assignment of intake camshaft (1) and exhaust camshaft (2).

Camshaft code numbers

*BE05.20-N-1001-01C

9

Install camshaft bearing cap (10)

AR05.20-D-6992-04NA

Topical note

Marking on camshaft bearing caps

Motor 647.981

AH05.20-P-6992-04HE


Intake camshaft (1) and exhaust camshaft (2) are very fragile.
Ensure they are installed free of tension.

 Screw/bolt, camshaft bearing cap to cylinder head

*BA05.20-P-1001-01F

10

Install camshaft timing gear (8) with mounted timing chain and new bolts (6) on exhaust camshaft (2)

 Take into account dowel pin (7). Counterhold exhaust camshaft (2) if necessary with open end wrench.

 Bolt, camshaft sprocket to exhaust camshaft

*BA05.10-P-1003-01A

11

Install chain tensioner (4)

AR05.10-D-7800NB

12

Check basic position of intake camshaft (1) and exhaust camshaft (2)

AR05.20-D-6010NB

Where necessary after check:



Correct basic position of intake camshaft (1) and exhaust camshaft (2).

AR05.20-D-6025NA

13

Install front cover (5) at cylinder head

AR01.30-D-5700NB

14

Install cylinder head cover

AR01.20-D-5014NB

Camshaft code numbers

Number

Designation

Engine 647.981

BE05.20-N-1001-01C

Camshaft code numbers

Intake

04

Exhaust

00

 Timing chain, chain tensioner

Number

Designation

Engine 647.981

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

 Camshaft

Number

Designation

Engine 647.981

BA05.20-P-1001-01F

Screw/bolt, camshaft bearing cap to cylinder head

Nm

9