Remove/install camshafts

AR05.20-S-6992C

Remove/install camshafts

06.02.2019

Engine

611.980 in model 638.094/194/294

with code MQ4 (Engine OM611 DE22 LA (75 kW))

with code MQ5 (Engine OM611 DE22 LA (90kW))

Engine

611.980 in model 638.094/194

with code MQ3 (Engine OM611 DE22 A (60kW))

1

Exhaust camshaft

6

Exhaust camshaft sprocket

11

Sealing ring

2

Intake camshaft

7

Dowel pin

12

Screw

3

Retaining pin

8

Camshaft bearing cap

A

Hole

4

Cylinder head cover

9

Screw

B

Hole

5

Intake camshaft sprocket

10

Chain tensioner



Remove

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove injectors

AR07.16-S-1000A

Topical note

Notes on injectors

AH07.16-P-1000-01A


Replace injector sealing ring and screws
of clamping claws.

Special grease

*BR00.45-Z-1036-06A

 Impact extractor

*602589003300

 Extraction claw

*611589013300

 Round brush

*611589006800

 Brake caliper brush

*000589266800

 External Torx set

*001589760900

2

Remove cylinder head cover (4)

AR01.20-S-5014D

3

Position piston of cylinder 1 to ignition TDC

AR01.00-S-0120D

 Rotate engine at crankshaft.

4

Install retaining lock for crankshaft/starter ring gear

AR03.30-S-5000C

5

Lock intake camshaft (2)

 Insert retaining pin (3) through first camshaft bearing cap into bore (A) in intake camshaft sprocket (5).

 Retaining pins

*111589031500

6

Remove chain tensioner (10)

AR05.10-S-7800D

7

Remove front cover at cylinder head

AR01.30-S-5700A

8

Remove upper slide rail

AR05.10-S-8432C

9

Mark intake camshaft sprocket (5) relative to timing chain

 For work that does not involve the rotation of the crankshaft, connect intake camshaft sprocket (5) and timing chain with cable tie.

10

Unscrew exhaust camshaft sprocket (6) from exhaust camshaft (1)

 Bolt, camshaft sprocket to exhaust camshaft

*BA05.10-P-1003-01A

11

Remove exhaust camshaft sprocket (6)

 Take into account dowel pin (7) (arrow). Detach exhaust camshaft sprocket (6) with mounted timing chain.

12

Unscrew camshaft bearing cap (8)

AR05.20-P-6992-05A

Topical note

Marking on camshaft bearing caps

AH05.20-P-6992-04HE

 Take into account camshaft bearing cap (8) marking!

13

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



Install

14

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


Camshafts (1, 2) are fragile.
Ensure they are installed free of tension.


Mount camshafts (1, 2) so that both bores (B) in camshaft sprockets (5, 6) are facing each other and the markings of camshafts (1, 2) (arrows) and camshaft bearing cap (8) are in alignment.
Camshafts (1, 2) are very fragile. Ensure they are installed free of tension.

 Installation: Oil bucket tappet and camshaft bearing points, check bucket tappet for ease of movement. Align intake and exhaust camshafts (1, 2) at axial bearing (arrows).

 Observe camshaft assignment!
Camshaft code numbers must be read off at thrust collar of axial bearing.

Camshaft code numbers

*BE05.20-N-1001-01C

Timing of intake/exhaust valve with 2 mm valve lift and run-in timing chain

*BE05.20-P-1001-02A

Timing of intake/exhaust valve with 2 mm valve lift and run-in timing chain

*BE05.20-P-1002-02A

15

Remove retaining lock

AR03.30-S-5000C

16

Turn piston of cylinder 1 to 30° BTDC

AR01.00-S-0120D


Crank engine at crankshaft, do not crank engine at bolt of camshaft sprocket (5, 6).
Do not rotate engine backwards.

 Markings of camshaft/camshaft bearing cap (8) (arrows) must be in alignment.

17

Mount camshaft bearing cap (8)

AR05.20-P-6992-05A

Topical note

Marking on camshaft bearing caps

AH05.20-P-6992-04HE

 Mount camshaft bearing cap (8) in reverse order at same location. Tighten bolts (12) evenly in increments of, in each case, 1 revolution.

 Observe camshaft bearing cap (8) marking.

 Screw/bolt, camshaft bearing cap to cylinder head

*BA05.20-P-1001-01F

18

Turn piston of cylinder 1 to ignition TDC

AR01.00-S-0120D

19

Lock intake camshaft (2)

 Insert retaining pin (3) through first camshaft bearing cap (8) into bore (A) in intake camshaft sprocket (5).

 Piston of cylinder 1 must be at ignition TDC for a locked intake camshaft (2).

 Retaining pins

*111589031500

20

Mount exhaust camshaft sprocket (6) at exhaust camshaft (1)

 Installation:
Replace bolts (9) of exhaust camshaft sprocket (6). Take into account dowel pin (7) (arrow).
Install exhaust camshaft sprocket (6) with mounted timing chain.

 Bolt, camshaft sprocket to exhaust camshaft

*BA05.10-P-1003-01A

21

Install chain tensioner (10)

AR05.10-S-7800D

 Replace the sealing ring (11).

22

Check basic position of camshafts (1, 2)

AR05.20-S-6010C

Where necessary after check



Adjust basic position of camshafts (1, 2)

AR05.20-S-6020B

23

Install cylinder head cover (4)

AR01.20-S-5014D

24

Install injectors

AR07.16-S-1000A



Check

 Warning

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

25

Check for oil leaks with engine running

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

26

Check fuel system for leaks with engine running

27

Read out fault memory and clear



AD00.00-P-2000-03A

Stored faults in the fault memories that could be caused by detached lines or a simulation during assembly or inspection work must be processed and cleared at the end of work. See



Diagnosis manual Diesel Engine Volume 1.2

Camshaft code numbers

Number

Designation

Engine 611.980

BE05.20-N-1001-01C

Camshaft code numbers

Intake

01

Exhaust

00

Timing

Number

Designation

Engine 611.980

BE05.20-P-1001-02A

Timing of intake/exhaust valve with 2 mm valve lift and run-in timing chain

Inlet valve

Opens ATDC

°KW

19

Closes ABDC

°KW

7

Timing

Number

Designation

Engine 611.980

BE05.20-P-1002-02A

Timing of intake/exhaust valve with 2 mm valve lift and run-in timing chain

Outlet valve

Opens BBDC

°KW

9

Closes BTDC

°KW

22

 Timing chain, chain tensioner

Number

Designation

Engine 611.980

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

 Camshaft

Number

Designation

Engine 611.960/961/962/980/981/983/987, 612.961/962/963/965/966/967/981/990, 613.960/961

BA05.20-P-1001-01F

Screw/bolt, camshaft bearing cap to cylinder head

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10