Remove/install camshaft housing

AR05.20-W-6995H

14.12.2018

Engine

470.9, 471.9 in model 963, 964

Modification notes

12.09.2018	Notes on safety relevant component parts, added.		AH00.00-Z-0019-01A
12.09.2018	Seal connections of the rail with protective covers, added.	Operation step 17
12.09.2018	Seal connections of the fuel injectors with protective covers, added.	Operation step 19

W05.20-1037-08

Shown on engine 471.9 up to engine end number 124618

1	Cylinder head cover	5	Fuel high-pressure lines	B601	Camshaft position sensor
2	Intermediate frame	6	High-pressure lines	B622	Rail pressure sensor
3	Engine wiring harness	7	Fuel return line
4	Camshaft housing	8	Sealing rings

Shown on engine 470.9

4	Camshaft housing
10	Bracket (only on engine 470.9)
11	Coolant line (only for engine 470.9)
12	Ventilation pipe (only for engine 470.9)

W05.20-1053-06

W05.20-1047-08

Shown on engine 470.9

4	Camshaft housing	12	Ventilation pipe (only for engine 470.9)	Y625	Engine brake solenoid valve, stage 2
5	Fuel high-pressure lines	13	Bracket (only on engine 470.9)
9	Adapter set	Y624	Engine brake solenoid valve, stage 1

 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
 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 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 self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Notes on safety-relevant components		AH00.00-Z-0019-01A
 	Remove/install
1	Tilt cab.	 Installation: Only tilt back cab after the leak test.
2	Remove noise encapsulation.
3	Remove premuffler with bracket.	Only on vehicles with code M5Y (Engine version Euro VI).
			AR49.10-W-4930H
4	Remove the cylinder head cover (1).	Engine 471.9	AR01.20-W-5014HA
		ENGINE 470.9	AR01.20-W-5014HB
5.1	Remove intermediate frame (2).	Engine 470.9 up to engine end number 222433, 471.9 up to engine end number 124618
			AR01.20-W-5016H
5.2	Remove wiring harness of the fuel injectors.	Engine 470.9 as of engine end number 222434, engine 471.9 as of engine end number 124619,
			AR07.16-W-1008H
6	Attach adapter set (9) to the camshaft housing (4).	 Adapter set	*470589026300
7	Mount turning device onto 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
		 Bolt, turning device to timing case	*BA01.60-N-1002-01N
		 Turning device	*904589046300
8	Set engine to ignition TDC on cylinder 1 and engage.
	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
		 Do not change the ignition TDC setting or engagement during the removal/installation of the camshafts.
		 Installation:  Pull out drift on timing case and remove  template. Install crankshaft position sensor with the new sealing ring and attach the electrical connection to crankshaft position sensor if necessary.
		 Bolt, crankshaft position sensor to timing case	*BA07.04-N-1001-01H
		 Template	*470589062300
		 Template	*470589032300
		 Turning device	*904589046300
		 Drift	*470589001500
9	Remove rocker arm assembly.	Intake rocker arm assembly	AR05.00-W-5521HA
		Exhaust rocker arm assembly	AR05.00-W-5521HB
10	Disconnect electrical connection on camshaft position sensor (B601).
11	Disconnect electrical connection from rail pressure sensor (B622).
12	Expose engine wiring harness (3) in the area of the camshaft housing (4).
13	Remove the bracket (10) of the coolant line (11) from the camshaft housing (4).	Only for engine 470.9
14	Remove bracket (13) of the compressor air intake hose.	Only for engine 470.9
15	Remove high-pressure lines (6) to rail.	Engine 470.9, 471.9 as of engine end number 032691	AR07.16-W-1004HA
		Engine 471.9 up to engine end number 032690	AR07.16-W-1004H
16	Remove fuel return line (7) from the rail.	 Installation: Install new sealing rings.
		 Engine 470.9, 471.9Banjo bolt, fuel line to rail (pressure limiting valve return)	*BA07.16-N-1024-03A
17	Seal connections of the rail with protective covers.	 Do not reuse  protective covers. If reused, contamination may damage the diesel injection system.
		 Set of protective covers	*470589279100
18	Remove fuel high-pressure lines (5) to the fuel injectors.		AR07.16-W-1003H
19	Seal connections of the fuel injectors with protective covers.	 Do not reuse  protective covers. If reused, contamination may damage the diesel injection system.
		 Set of protective covers	*470589279100
20	Remove screws of the camshaft housing (4).	Tightening procedure	AR05.20-W-6995-01H
		 Unfasten screw/bolts in reverse order of the tightening procedure.
		 Bolt, camshaft case with rocker arm bracket to cylinder head	*BA05.20-N-1001-04A
21	Remove camshaft housing (4) with camshafts.	 Installation: Check marking on the camshaft sprockets relative to the markings on the  template; align camshaft sprockets if necessary. Select marking on the  template according to the piston displacement variant.
		 For engine 470.9 Installation: Introduce the ventilation pipe (12) into the camshaft housing (4).
		 Template	*470589062300
		 Template	*470589032300
22	Remove seal from camshaft housing (4).	 Installation: Clean sealing surfaces on cylinder head and camshaft housing (4). Replace seal.
23	Remove sealing ring of the vent tube (12).	Only for engine 470.9.
		 Installation: Replace sealing ring.
24	Remove template and adapter set (9) from the camshaft housing (4).	Only when installing new camshaft housing (4).
25	Remove seals (8).	Only when installing new camshaft housing (4).
		 Installation: Install new seals (8).
26	Pull engine brake solenoid valve, stage 1 (Y624) and engine brake solenoid valve, stage 2 (Y625) out of the camshaft housing (4).	Only when installing new camshaft housing (4).
		 Installation: Install new sealing rings.
27	Remove camshaft position sensor (B601) from camshaft housing (4).	Only when installing new camshaft housing (4).
		 Installation: Replace sealing ring.
		 Bolt, camshaft position sensor to camshaft housing	*BA05.20-N-1003-01P
28	Remove camshafts.	Only when installing new camshaft housing (4).
			AR05.20-W-6992H
29	Remove rail.	Only when installing new camshaft housing (4).
			AR07.03-W-1010H
30	Install in the reverse order
31	Perform engine test run.
32	Check engine in the area of the cylinder head cover (1), intermediate frame (2), and camshaft housing (4) for leak tightness.	 Visual inspection.

 Timing case

Number	Designation		Engine 470.9, 471.9
BA01.60-N-1001-01N	Screw/bolt, cap of TDC inspection hole to timing case	Nm	30

 Timing case

Number	Designation		Engine 470.9, 471.9
BA01.60-N-1002-01N	Bolt, turning device to timing case	Nm	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

 Camshaft

Number	Designation		Engine 470.9, 471.9, 473.9
BA05.20-N-1003-01P	Bolt, camshaft position sensor to camshaft housing	Nm	10

 Sensors

Number	Designation		Engine 470.9, 471.9, 473.9
BA07.04-N-1001-01H	Bolt, crankshaft position sensor to timing case	Nm	10

 Common rail diesel injection system

Number	Designation			Engine 470.9	Engine 471.9## ## up to 032690
BA07.16-N-1024-03A	Banjo bolt, fuel line to rail (pressure limiting valve return)	M14x1.5	Nm	30	30