Remove/install cylinder head

AR01.30-D-5800E

Remove/install cylinder head

6.4.99

29.6.01

Value changed from 30 Nm to 18 (2) Nm

Value in BA09.40-P-1004-01C for engine 611.981/983/987 modified

*BA09.40-P-1004-01C

 

Remove/Install

1

Disconnect ground cable at battery

Danger!

Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

2

Drain coolant, pour in

 At radiator and crankcase

AR20.00-D-1142A

3

Remove camshafts

AR05.20-D-6992D

4

Take out hydraulic valve clearance compensation elements (23)

5

Take off camshaft housing (1) at cylinder head

 Installation: When fitting on, pay attention to dowel sleeves (2) for locating the camshaft housing.

6

Remove high pressure pump intermediate gear (13)

AR05.10-D-4650A

7

Disconnect engine wiring harness at engine side

AR15.18-D-1000-01A

8

Detach bottom part of charge air distribution pipe at cylinder head and place to the side with engine wiring harness connected

 The engine wiring harness does not need to be separated at the vehicle side.

AR09.41-D-1313A

9

Detach oil feed line (19) at cylinder head and at turbocharger (18)

 Replace seal (120).

 at turbocharger

*BA09.40-P-1004-01C

 at cylinder head

*BA09.40-P-1005-01C

10

Detach turbocharger (18) at exhaust manifold (16)



*BA09.40-P-1001-01C

11

Detach coolant pipe (21) at cylinder head and push to the side with coolant lines connect

12

Detach coolant hoses (9, 11) at coolant thermostat housing

 Inspect condition of coolant hoses and collar clamps (10, 12), replace if necessary.

13

Slacken bolt (8) at bracket of fuel filter, take out fuel filter (7) and place to the side with fuel lines connected

14

Detach fuel line (3) at rear at rail and unclip at front at fixture

 Handle securing clip carefully.

AR47.25-P-1000-01A

 Collect escaping fuel.

Replace sealing ring

15

Detach coolant hose (5) at rear at pipe of exhaust gas recirculation/ rear cylinder head connection fitting

16

Unscrew bolts (26) of cylinder head at timing case cover

 Installation: Pay attention to tightening pattern of bolts (26) and of cylinder head bolts (25).



*BA01.30-P-1005-01A

17

Slacken cylinder head bolts (25) in stages, unscrew

 Slacken cylinder head bolts in reverse order of tightening diagram once engine has cooled down 

Tightening diagram of cylinder head bolts.

AR01.30-P-5800-01HB

 Installation: Oil and insert cylinder head bolt at thread and bolt head contact surface It is not necessary to retighten the cylinder head bolts.



*BA01.30-P-1007-01A

18

Inspect cylinder head bolts (25), replace if necessary

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

19

Take cylinder head (24) off the crankcase

 Installation: Place new cylinder head gasket (27) on crankcase. When fitting on, pay attention to dowel sleeves (28) for locating the cylinder head.

20

Clean contact surfaces and threaded holes

 Blow out threaded holes, free of oil and water, inspect contact surfaces, if necessary 

Check cylinder head separating surface.

21

Install in the reverse order

22

Bleed low pressure fuel circuit

AR07.16-D-0100A

23

Inspect cooling system for leaks

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-D-1010C

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

24

Inspect for oil leaks

 Run engine until warm, switch off and inspect for leaks.

 Danger!

Risk of explosion from fuel igniting. Risk of injury. Fuel may stream out and cause injury to eyes or skin.

Keep all ignition sources out of hazardous area.

Do not carry out any work on the system when it is pressurized.

AS07.16-Z-0001-01A

25

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

26

Encode radio, set clock

Number

Designation

Engine 611.981/983/987

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

max. length (L)

mm

104

Fig., see

AR01.30-P-5800-03HB

Number

Designation

Engine 611.981/
983/987

BA01.30-P-1005-01A

Bolt of cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1006-01A

Bolt of front cover to cylinder head

Nm

14

BA01.30-P-1007-01A

Bolt of cylinder head to crankcaseM12

1st stage

Nm

60

2nd stage

°

90

Step 3

°

90

Number

Designation

Engine 611.981/
983/987

BA09.40-P-1001-01C

Flange connection of exhaust manifold to turbocharger

Nm

30

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw socket

Nm

-

Banjo bolt

Nm

18 (2)

BA09.40-P-1005-01C

Bolt of oil feed line to cylinder head

Nm

9

Number

Designation

WH58.30-Z-1001-06A

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

WH58.30-Z-1002-06A

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10