Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 392
(7) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
NOTE: The lower portion of the cylinder head front
cover is sealed with RTV sealant. Carefully tug front
cover after bolt removal to loosen from cylinder
head.
(8) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(9) Remove top side rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
CAUTION: For all work in which the crankshaft
should not rotate, secure camshaft gear to timing
chain.
(10) Mark camshaft sprocket relative to timing
chain.
(11) Unbolt camshaft sprocket from exhaust cam-
shaft.
NOTE: Note the position of dowel pin for camshaft
sprocket alignment during reassembly.
(12) Remove camshaft sprocket.
CAUTION: Camshaft bearing caps must remain in
proper order and position.
NOTE: Slacken the bolts of the camshaft bearing
caps evenly in steps of one turn until the back
pressure is eliminated. Camshafts must not be
twisted when slackening the camshaft bearing
caps.
(13) Paint mark or scribe each camshaft bearing
cap, identifying which camshaft and which position.
(14) Remove the camshaft bearing caps at exhaust
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(15) Remove the camshaft bearing caps at intake
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(16) Slacken the exhaust camshaft bearing cap
bolts individually at the #2 cap then the #5 cap in
steps of one revolution until the back pressure is
removed.
(17) Slacken the intake camshaft bearing cap bolts
individually at the #2 cap then the #5 cap in steps of
one revolution until the back pressure is removed.
(18) Remove the inlet and exhaust camshafts (Fig.
22).
NOTE: Inspect camshaft and housing for wear or
damage. Inspect the housing oiling ducts for build
up or restrictions, clean as necessary. Also inspect
the camshaft end cover for wear or damage, replace
camshaft as necessary.
Fig. 21 CAMSHAFT ALIGNMENT
1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN MARKING
2 - EXHAUST CAMSHAFT SPROCKET BOLTS
3 - EXHAUST CAMSHAFT SPROCKET
4 - CAMSHAFT ALIGNMENT DOTS
5 - INTAKE CAMSHAFT LOCK POSITION
6 - INTAKE CAMSHAFT SPROCKET
7 - INTAKE CAMSHAFT LOCK (SPECIAL TOOL #8929)
8 - INTAKE CAMSHAFT SPROCKET
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ENGINE
9 - 31
INSTALLATION
CAUTION: The camshafts are sensitive to fractur-
ing. Ensure they are installed free of stress. Oil
bucket
tappets
and
camshaft
bearing
points.
Inspect ease of operation of bucket tappets.
CAUTION: Pay attention to assignment of cam-
shafts. Camshaft code numbers are visible on the
thrust collar of the axial bearing. Install camshafts
so that the two holes in camshaft sprockets are
positioned opposite and the markings of the cam-
shaft and camshaft bearing cap are aligned.
(1) Install inlet and exhaust camshafts.
NOTE: Tappets are Only serviced when replacing
the camshaft housing. Inspect tappet clearence
(Refer
to
9
-
ENGINE/CYLINDER
HEAD/CAM-
SHAFT(S) - STANDARD PROCEDURE).
(2) Align inlet and exhaust camshafts at axial
bearing (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
NOTE: Pay attention to markings on camshaft bear-
ing caps.
CAUTION: Do not rotate engine counter clockwise.
(3) Position the piston of cylinder #1 to ignition
TDC.
NOTE: Pay attention to markings on camshaft bear-
ing caps and follow the tightening procedure below.
(4) Install the #2 and #5 Exhaust cam bearing
caps (Fig. 23).
(5) Install the #2 and #5 Intake cam bearing caps
(Fig. 23).
(6) Tighten each of the #2 and #5 Intake and
Exhaust bearing cap bolts evenly to 9N·m (80 lbs.
in.) in steps each of 1 revolution (Fig. 23).
(7) Install the remaining Intake and Exhaust cam
bearing caps and tighten them evenly to 9N·m (80
lbs. in.) in steps each of 1 revolution (Fig. 24).
Fig. 22 CAMSHAFTS AND HOUSING ASSEMBLY
1 - CYLINDER HEAD BOLTS
2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
5 - CYLINDER HEAD
Fig. 23 CAMSHAFT BEARING TIGHTENING
SEQUENCE #1
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ENGINE
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NOTE: The piston of cylinder #1 must be positioned
at ignition TDC when the inlet camshaft is locked.
(8) Insert locking pin through the first camshaft
bearing cap into the whole in the camshaft sprocket.
NOTE: Do Not use old camshaft sprocket bolts.
(9) Fit camshaft sprocket with timing chain fitted
on, onto exhaust camshaft paying attention to posi-
tion of dowel pin. Tighten bolt to 18N·m (159 lbs.in.).
(10) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(11) Inspect/Set basic position of camshafts (Refer
to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
STANDARD PROCEDURE).
(12) Insert slide rail and bolt the driver into the
inlet camshaft. Tighten bolt driver to 50N·m (37 lbs.
in.).
(13) Install front cover at cylinder head.
(14) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
NOTE: Refer to the appropriate injector servicing
procedures for cleaning of injectors and recesses.
(15) Clean and install injectors (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE), (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(16) Reconnect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(17) Start engine and inspect for leaks.Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
(18) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect the air inlet and set aside.
(3) Detach hose from oil separator.
(4) Disconnect the camshaft position sensor.
(5) Disconnect fuel injector and glow plug harness
and set aside.
(6) Remove fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(7) Disconnect the out let line.
(8) Remove cylinder head cover retaining bolts and
remove cover (Fig. 25).
Fig. 24 CAMSHAFT BEARING TIGHTENING
SEQUENCE #2
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ENGINE
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INSTALLATION
NOTE: Do Not tighten the cylinder head cover first.
The fuel injectors are aligned by way of the cylinder
head cover.
(1) Fit cylinder head cover with new gasket and
install bolts, hand tight (Fig. 25).
(2) Insert all fuel injectors, tensioning claws and
lines. Insert new bolts and tighten. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(3) Tighten cylinder head cover bolts to 9 N·m (80
lbs. in.).
(4) Install and properly route fuel injector and
glow plug wiring harness, making appropriate con-
nections.
(5) Connect the camshaft position sensor.
(6) Connect the return flow line.
(7) Attach oil separator hose.
(8) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(9) Start engine and inspect for leaks. Care must
be take to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide. For servicing of the valve seals
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
SPRINGS - REMOVAL).
Fig. 25 CYLINDER HEAD COVER
1 - ENGINE WIRING HARNESS
7 - GASKET
2 - GLOW PLUG CONNECTOR
8 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
9 - CRANKCASE VENT LINE
4 - OUTLET LINE
10 - GASKET
5 - INTAKE MANIFOLD
11 - FUEL INJECTOR
6 - GASKET
12 - GROUND
9 - 34
ENGINE
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