ENGINE Engine Timing - Model 906 TESTING & REPAIR REMOVE/INSTALL HYDRAULIC VALVE CLEARANCE COMPENSATING ELEMENTS - ARO05.00-S-2011SE. ENGINES 642.896 /898 /992 /993 in MODEL 906 Engine 642 In Model 639) REMOVE/INSTALL HYDRAULIC VALVE CLEARANCE COMPENSATING ELEMENTS - ENGINE 642 IN MODEL 906 lelements (1) by [Remove/install i [Remove camshafts [Model 906 AR05.20-D-69925F| 2 [Pry off clamps (2) B [Detach compensating jelements (1) for roller-type lcam follower (3) ls [Remove roller drag lever (3) Ss [Remove compensating (® Do not use magnets. This lwould magnetize the contact surfaces of the compensation lelement (1) and the roller drag llever (3). Tiny iron filings |could gather in this way which] lcould lead to damage on the compensating element (1), the Lroller-type cam follower (3){and the camshaft. (71 Installation: |Compensating element (1) lwhich were not replaced must be installed again at the same installation location. 6 install in the reverse order TESTING & REPAIR WORK: LIGHT TRANSPORTERS: ENGINE TIMING - AR05.00-Z-9642EB ENGINE 642 TESTING & REPAIR WORK: LIGHT TRANSPORTERS: ENGINE TIMING - ENGINE 642 [Removelinstall hydraulic valve IENGINES 642.896 898 992 993in | AROS.00-S-20115] clearance compensating elements IMODEL 906 |Removelinstall valve springs andlor _ [ENGINES 642.896 /898 1992 1993 in valve stem seals IMODEL 906 TESTING & REPAIR WORK: TRANSPORTERS: ENGINE TIMING - AR05.00-Z-9642EB ENGINE 642 TESTING & REPAIR WORK: TRANSPORTERS: ENGINE TIMING - ENGINE 642 [Check basic position of camshafts ENGINE 642.896 /898 /992 /993 in MODEL 5.20-D-60105) lo06 Check timing chain [ENGINE 642.896 /898 /992 993 in MODEL 5.10-D-76005) lo06 |Remove/install camshaft sprocket [ENGINES 642.896 /898 /992 /993 in 5.20-D-60405) IMODEL 906 [Remove/install camshafts [ENGINE 642.896 /898 /992 /993 in MODEL | ARO05.20-D-69925F| lo06 [Remove/install chain tensioner [ENGINES 642.896 /898 (992 /993 in 5.10-D-73 IMODEL 906 [Remove/install hydraulic valve NGINES 642.896 /898 /992 /993 in’ ‘AR05.00-8-20115E| clearance compensating elements _ [MODEL 906 [Remove install slide rails and [ENGINES 642.896 /898 (992 /993 in 5.10-D-84245) tensioning rail IMODEL 906 |Remove/install valve springs and/or [ENGINES 642.896 /898 /992 /993 in 5.30-5-351 |valve stem seals IMODEL 906 [Remove install valves [ENGINES 642.896 /898 (992 /993 in }5.30-D-3511SG| IMODEL 906 [Replace timing chain [ENGINES 642.896 /898 (992 /993 in 5.10-D-76015) IMODEL 906 CHECK TIMING CHAIN - AR05.10-D-7600SEENGINE 642.896 /898 /992 /993 in MODEL 906 Sean an Canats sow TOC mang ‘now 81° taro Coos ene meng Fig. 2: Timing Chain Component Locations - Engine 642 CHECK TIMING CHAIN - ENGINE 642.896 /898 /992 /993 IN MODEL 906 [Remove/install [Place piston of cylinder I at lignition TDC and check lbasic position of camshafts only remove right cylinder lhead cover: AR05.20-D-6010SF| lof timing chain (4) (3) in right cylinder head a [Lock camshafts (3) by Fig.3 jinserting retaining pin (2) in| Ibores (1) my |Checking 3 [Continue to turn engine at (® Do not tum engine against lvibration damper (6) in direction of engine rotation |direction of engine rotation otherwise false measurements luntil slight resistance is will occur; repeat the turning lnoticeable laction if necessary. [Do not turn engine by force. [4 [Determine chain elongation i The timing chain (4) is still within permissible tolerance if| le stay on timing case cover \(5) between the top dead \center marking (arrow A) and 11° after top dead center marking (arrow B). [The timing chain (4) must be replaced if this is not the case(See: ? eplace timing chain (4) AR0S.10-D-76018F| 5 [install in the reverse order 589.03 1500 Reine pat ii identifying Retaining Pins (111 589 03 0) DISCONNECT TIMING CHAIN - AR05.10-D-7601-01SF ENGINES 642.896 /898 /992 /993 in MODEL 906 (602 589 00 98 00 case identi se (602 00 98 00) 02.3300 1 separating to!ga 802 689 04 63.00 602 589 04 63.01 ustpe ident Thrust, 642 589 04 4000 Fig. 8: Identifying Hold-down Device (642 589 04 40 00) @® Parts, which have fallen into timing case recess or cylinder head must be removed in order to avoid damage to the engine 1. @ insert pressure pin (1) in ¥] pressure screw (2) and [¥] tighten union nut (3). 2. BW) screw pressure pin (2) into ¥] guide sleeve (4). LG The 1 pressure pin (1) must not project into beveled tapered area of [¥] guide sleeve (4). 3. MW screw gu fe sleeve (4) into [7] chain separating tool (5).05.0 Fig. 9: Identifving Pressure Pin, Screw Pressure Pin, Union Nut, Guide Sleeve & Separating Tool - Engine 642 4, Attach PJ hold-down device (6) to cylinder head,Fig. 1 der Head ttaching Hold-Down Device To Cover timing case recess and cylinder head with shop towels. (Fit chain separating tool (5) onto timing chain (7), screw guide sleeve (4) into (] chain separating tool (5) until the openings on the [¥] guide sleeve (4) and [J the guide (Sa) surround the timing chain bolt (8). [1 Press pressure screw (2) [¥1 into guide sleeve (4) and press out the timing chain bolt (8).os. 10-9935-12 Fig. 11: Using Chain Separating Tool To Press Out Timing Chain Bolt 9, Remove ¥] pressure pin (2) [¥] from guide sleeve (4) and remove [¥] chain separating tool (5). 10, Remove timing chain bolt (8) from the [¥] guide (5a).RIVET TIMING CHAIN - AR0S.10-D-7601-02SF BOLT FOR TIMING CHAIN RIVET ELEMENT TORQUE SPECIFICATION [Number Designation [BA0S.10-N-1005-01G [Bolt for timing chain rivet element (reference value) Nail Engine 642| 32 Fi 112 689 09 63 00 Assent nsers 3: Identifving Assembly Inserts (112 589 09 63 00602 689 00 1602 589 00 98 00 case [dentifving Case (602 589 00 98 00) 602 689 02 63.00 Assembyinsens identi ssembly Inserts (602 589 02 63 00) 602 589 03 6300Fig. 17: Identifving Thrust Piece (602 589 03 63 00) ® Parts, which have fallen into timing case recess or cylinder head must be removed in order to avoid damage to the engine 1. Cover timing case recess and cylinder head with shop towels. 2. Insert new riveted link (4) and new middle plate (3) together with [¥] centering fork (1) into the ends of the new timing chain (2). The new center axle (3) is secured with the [7] centering fork (1). ost0-114241 Fig. 18: Inserting Centering Fork Into Ends of Timing Chain 3. Bl) insert and tighten assembly insert (6) with the digit FS into the ¥] riveting tool (5). 4. Place assembly insert (7) with the digit D9 into the 7 riveting tool (5). @ The #1] assembly insert (7) is able to move on #1] pressure screw (8) and is loosely mounted.er0N41-01 Tool & Pressure Screw 5. Bottom [¥] rivet press tool (5) in such a way that the new timing chain (2) that the [¥] assembly insert (7) touches the new riveted link and the [¥] centering fork (1) can be pressed out. 6. Screw in &] thrust spindle (8) and press in new riveted link up to the stop. Remove 1] centering fork (1). G) Ensure that riveted link and ¥] assembly insert (7) are aligned. Do not allow the [7] centering fork (1) which is pressed out to drop into the timing case recess, 7. BW) Remove pressure screw (8) and [¥] rivet press tool (5). 8, SRemove assembly inserts (6, 7) from Z] rivet press tool (5). Fig. 2 9, WZ insert and tighten assembly insert (9) with the digit F1 into the [J riveting tool (5). 10, @ Insert thrust piece (10) with digit D8 into the [4] riveting tool (5)i 13 14. Insert new outer plate (11) into the thrust piece 1 (10). i The new outer plate (11) is held firmly by the magnetic [¥] thrust piece (10). Fig. 2: Outer Plate & Thrust Piece Place IY] rivet press tool (5) in such away that the spacer bushing of the ¥] assembly insert (9) lies on the roll of the timing chain (2) (arrows). G1) Ensure that riveted link and new outer plate are aligned. ©] screw in pressure screw (8) on J rivet press tool (5) until there is firm resistance. Gi White pressing on ensure that the bolt of the new rivet link in the bores break in the new outer plate. (Remove pressure screw (8) and ¥] rivet press tool (5).16. V7. 18. 19. ig. 23: Identifying Pressure Screw & Rivet Press Tool Turn ¥] thrust piece (10) in the I rivet press tool (5) on the rivet profile (arrow). os 10-1 Fis identifying Thrust Piece & Rivet s To Fit rivet press tool (5) at the center onto one of both timing chain pins of the new riveted link (arrow). Tighten (¥] thrust spindle (8) of the [¥] rivet press tool (5) and rivet first timing chain bolt for the new riveted link. 1 Observe tightening torque. 1 Loosen pressure screw (8) by turning and 1 place rivet press tool (5) on second first timing chain bolt for the new riveted link. (1 Tighten pressure screw (8) on [¥] rivet press tool (5) and rivet second timing chain bolt.Gi observe tightening torque. 20. Loosen pressure screw (8) and [¥] remove rivet press tool (5). 602 589 02 40 00 ASSEMBLY LINKS - WS05.00-P-0171C FG 05/18/Set C E INE all Use: Assembly links (3 in total) for simplex roller chain, duplex roller chain and duplex bushed roller chain for connecting repair chain to installed chain @H Assembly links must not be left in the engine. ("00 Gl ol GB ots > \ sna s9.02.40. 09 Fig, 98: Identifving Assembly Links (602 589 02 40 00 271 589 00 59 00 ASSEMBLY TOOL - WS05.00-P-0202C FG 05/Set C ENGINE all Use: This assembly tool is used for mounting cylinder heads. 00 i a aFig. 99: Identifying Assembly Tool (271 589 00 59 00) 271 589 09 63 00 ASSEMBLY ELEMENT - WS05.00-P-0228B FG 03/05/Set B ENGINE 642 Use: Assembly element for connecting the repair chain with the installed chain when changing the timing chain. NOTE: The assembly element must not be left in the engine! (P00 ll \. 271. [Link] __ Fig. 100: Identifying Assembly Element (271 589 09 63 00) 642 589 01 40 00 TIE-DOWN SET - WS05.00-P-0229B. FG 05/Set B ENGINE 642MODIFICATION NOTES - 642 589 01 40 00 TIE-DOWN SET 9.10.06 Replaced by 642 589 04 40 00] Use: Tie-down sets hold the timing chain in mesh with the camshaft sprocket. =o \ 62 sa9.0t 4o.00 _ Fig. 101: Identifying Tie-Down Set (642 589 01 40 00) 642 589 00 31 00 HOLD-DOWN DEVICE KIT - WS 0-P-0230€ FG 05/Set C ENGINE 642 Use: Bearing bridge (2 pieces) for fixing camshafts for an opened valve cover 0 an a aFig. 102: Identifying Hold-down Device Kit (642 589 00 31 00) 640 589 00 61 00 DEPRESSOR - WS05.00-P-0236B FG 05/Set B E INE 640, 642 Use: Depressor for valve spring retainer (00 a a \ 0 se0.006100 Fig. 103: Identifving Depressor (640 589 00 61.00) 642 589 04 40 00 TIE-DOWN SET - WS05.00-P-0257B FG 05/Set B ENGINE 642 MODIFICATION NOTES - 642 589 04 40 00 TIE-DOWN SET [9.10.06 Replacement for 642 589 01 40 00] Use: Tie-down sets hold the timing chain 0 a a in mesh with the camshaft sprocket.Fig. 104: Identifying Tie-Down Set (642 589 04 40 00) 642 589 00 33 00 RIVETING TOOL - WS05.00-P-0260C FGO5/18/Set C ENGINE all MODIFICATION NOTES - 642 589 00 33 00 RIVETING TOOL 20.11.07 [Replacement for 602 589 00 39 00 20.11.07 [Replacement for 272 589 00 39 00 Use: Rivet press tool (basic unit) to rivet timing chains. Assembly inserts 651 589 04 63 00 should be used for engine 651. << GER ABS \ 2 589 00 33.0 Fig. 105: Identifying Riveting Tool (642 589 00 33 00) 111 589 25 61 00 VALVE ASSEMBLY TOOLS KIT - WS05.00-P-3137BA,ENGINE 642 111 589 25 61 00 VALVE ASSEMBLY TOOLS KIT T1589 2561 03 Lever handle [FGO5/SetC WS05.00-P-3137-03C] 11 589 25 61 05 Detent FGOS/Set C WS05.00-P-3137-05C| depressor 111 589 2561 06 Thrust fork |FGOS/Set C WS05.00-P-3137-06C| I11 589 25 61 12 Fixing bracket _|FGOS/Set C 11 589 25 61 19 Grid FGOS/Set C FG 05/Set B Assembly tool for valve springs in a plastic case. NOTE: For engines with tappet holes in cylinder head assembly of the valve keys is performed automatically by the assembly cartridges. Consisting of: Part 1 case empty Part 2 Impact bolt Part 3 Lever handle Part 4 Extension Part 5 Detent depressor for thrust piece Part 6 Thrust fork for assembly cartridgesPart 7 Thrust piece for detent depressor Part 8 Assembly cartridge length 83 mm (gasoline engine) Part 9 Assembly cartridge length 102 mm (diesel engine) Part 10 Pilot bushing length 28.6 mm (gasoline engine) Part 11 Pilot bushing length 53 mm (diesel engine) Part 12 Retaining fork M 6 X 15 mm Part 13 Retaining fork M7 X 25 mm Part 14 Retaining fork M7 X 30 (bolt length 60 mm) Part 15 Retaining fork M 8 X20 mm Part 16 Threaded hook M6 X 23 mm. Part 17 Threaded hook M7 X 23 mm Part 18 Threaded hook M8 X 20 mm Part 19 Grid with joint bearing SPECIAL TOOLS: COMMERCIAL VEHICLES: ENGINE TIMING - WS05.00-Z-9999TZ MODEL all SPECIAL TOOLS: COMMERCIAL VEHICLES: ENGINE TIMING [000 589 10 68 00 Cylinder FG 05/15/Set C brush [000 589 10 99 00 Tool kit _|FG 00 FG 05/07/23/31/ Set A [WS00.00-P-00302| 000 589 1099 01 Torque [FG 00/05/07/23/31/Set A ‘WS00.00-P-0030 wrench, o1Z/ [000 589 10 99 17 Open end |FG 00 FG 05/Set A ‘WS00.00-P-0030- wrench attachment, 15 mm. 17Z| 000 589 10 99 18 Open end |FG 00 FG 05/07/set A ‘WS00.00-P-0030 wrench attachment, 17 mm. 18Z| [000 589 20 21 00 Hardness [FG 00 FG 03/Set B FG 03/05/Set C tester 000 589 28 33 00 Puller dia. [FG 00/03/05/26/27/ 28/33/43/40/Set B I28-37 mm. 000 589 29 33 00 Internal [FG 00 FG 05/13/26/27/28/ 33/42/set C extractorIFG 00/03/05/26/27/ 28/33/43/46/Set B WS00.00. 00512 [000 589 34 33 00 Counter stay IFG 00 FG 03/05/13/18/25/26/28/33/35/42/46) Set C [001 589 00 91 00 Set of otective covers IFG 01/03/03/07/08) 001 589 02 91 00 Set of otective covers 05) [09/13/14/15/18/20/23/43/46/47/49/54/ Set B IFG 01/03/03/07/08) (09/13/14/15/18/20/23/43/46/47/49/54/Set B 0112B} 001 589 53 21 00 Dial gage IFG 00701/03/05/09) 13/18/23/26/28/33/35/41/42/46/83/Set B ‘WS00.00-N-| 00132 001 589 63 09 00 Socket FG 03/01/05/27Set B |WS03.00-P-0006B] 1001 589 78 21 00 Compression tester IFG 01/03/05/Set A 102 589 00 34 00 Threaded bolt IFG O1/05/Set B [WS05.00-P-00098| 1103 589 01 63 00 Assembly inserts IFG 05/18/Set C ‘WS05. 00. 0040C| 110 589 03 59 00 Mounting wedge IFG 00/01/05/13/18/26) [30/42/43/46/54/67/68/7 77/80/82/83/ 88/91/Set K 11 589 03 15 00 Retaining ins IFG 01/03/05/Set B 111 589 25 61 00 Valve assembly tools kit 3137BA\ 112 589 00 25 00 Squeeze gun IFG 00/01/05/18 {W00.00-P-00527| 112 589 09 63 00 Assembly inserts IFG 05/18/Set C 116 589 01 34 00 Threaded bolt [FG 01/03/05/ Set B 116 589 20 33 00 Impact extractor 1195890043 00D [FG 05/Set B ‘WS05.00-N-| 00988] 119 58901 1400 Sleeve _ [FG 03/05/Set B [WS03.00-P-00228| [210 589 00 40 00 Magnetic [FG 01/05/15/18/25/ Set B WS05.00-N. in 01558] J210 589 01 16 00 Four-point|FG 22/05/Set B [WS22.00-P-0006B| drive I271 589 00 59 00 Assembly [FG 05/Set C WS05.00-P- tool 0202C] J271 589 09 63 00 Assembly element IPG 03/05/Set B [WS05.00-P-0228B| 346 589 00 63 00 Supercooler box IFG 05/Set C[363 589 02 21 00 Dial gage holder [FG 00/01/03/05/09/ 13/18/26/28/33/35/41/42/ Set B 366 589 00 21 05 Extension [FG 00/01/03/05/09/13/18/23/26/28/33/35/41/42/83/Set IB 366 589 02 15 00 Drift IFG 05/26733/41/Set C [602 589 00 39 00 Riveting tool IFG 05/18/Set C 0162C) [602 589 00 98 00 Case [FG 03/05/18/Set C [502 589 02 33 00 Chain separating tool IFG 05/18/Set C [602 589 02 40 00 Assembly [FG 05/18/Set C WS05.00-P-| inks 0171€| [602 589 02 63 00 Assembly |FG 05/Set C WS05.00-P-| inserts 0163C| [602 589 03 63 00 Thrust [FG 05/Set C WS05.00-P-| eve 0163C| [602 589 04 63 00 Thrust [FG 03/05/Set C WS05.00-P-| spindle 0160C} [602 589 04 63 01 Pressure [FG 03/05/Set C WS05.00-P-0160. ins oc [602 589 05 63 00 Pressure [FG 05/18/Set C WS05.00-P-| screw 0161C| [602 589 05 63 01 Pressure [FG 05/18/Set C WS05.00-P-0161- Jpins oc [605 589 00 33 00 Puller IFG 05/Set B \WS05.00-P-0154B] [605 589 00 33 02 Puller bolt FG 05/01/Set B [606 589 00 37 00 Pliers [FG 05/Set B [606 589 00 37 00 Pliers [611 589 00 63 00 Connector FG 01/05/SetB [611 589 00 68 10 Round brushes (3 x) [FG 01/05/07/15/Set B [611 589 01 63 00 Female connector FG 01/05/Set B 611 589 02 63 00 lintermediate piece FG 01/05/Set B [617 589 00 40 00 Slip gauge lnolder IFG 05/Set A 1629 589 01 63 00 Engine turning device IFG 01/03/05/27/ Set B [629 589 02 63 00 Engine IFG 01/03/05/27/ Set Btuning device [640 589 00 61 00 Depressor [WS05.00-P-0236B| 642 5890031 00Hold- [FG O5/SetC down device kit [642 589 00 33 00 Riveting |FGOS/I8/Set C tool [642 589 01 40 00 Tie-down |FG 05/Set B [WS05.00-P-0229B| set [642 589 04 40 00 Tie-down [FG 05/Set B [WS05.00-P-0257B| set [668 589 00 68 00 Cylinder brush IFG 01/05/07/Set B [WS01.00-P-00618| [668 589 00 68 05 Cylinder brushes IFG 01/05/07/Set B ‘WS01.00-P-0061- OB