D01.30-0001-09
D01.30-1018-09
1 Cylinder head
2 Hexagon socket head bolt on timing case cover
3 Cylinder head bolt
4 Fuel filter
5 Hexagon nuts
6 Wiring harness of cylinder head
9 Coolant hose to rear of cylinder head
10 Coolant hose to front of cylinder head
11 Leak oil line
12 Injection lines
13 Fixture of injection lines
14 Vacuum line (brake booster)
15 Vacuum line
16 Cylinder head gasket
17 Hexagon bolt (tensioning device)
18 Hexagon bolt (dipstick guide tube)
20 Turbocharger
21 Exhaust pipe bracket
22 Pressure oil line
22 A Banjo bolt
22b Sealing ring
23 Shield
24 Connection, oil return flow line to crankcase
24 A Gasket
25 O-ring
26 Oil return line
27 Intake air hose
28 Charge air hose
30 Bracket for turbocharger to alternator support
| Remove/install | ||
1 | Disconnect ground cable from battery | ||
2 | Take off fixture of injection lines (13) | ||
3 | Detach leak oil lines (11) | ||
4 | Remove injection line (12) | | |
5 | Remove intake manifold | ||
6 | Remove camshaft | ||
7 | Remove oil-water heat exchanger | ||
8 | Slacken poly-V-belt, remove | Installation: Hexagon bolt (22) for attaching tensioning lever must be inserted into the cylinder head before installing the intake manifold. | |
9 | Unbolt dipstick guide tube at cylinder head (18) | | |
10 | Unscrew bolt (17) of shock absorber of poly-V-belt tensioning device to cylinder head | | |
11 | Remove fuel filter (4) | Place fuel filter to the side with lines connected and attach to the vehicle. | |
12 | Detach coolant hoses (9, 10) at cylinder head | ||
13 | Remove coolant pipe at cylinder head | ||
14 | Unplug electrical connections at the cylinder head | ||
15 | Pull out guide rail pins in cylinder head | ||
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Installation: Coat guide rail pins with sealant. | |||
16 | Unbolt shield (23) | ||
17 | Detach intake air hose (27) and charge air hose (28) at turbocharger | ||
18 | Unbolt exhaust pipe (31) from turbocharger (20) | Installation: Install new nuts. | |
19 | Unbolt bracket of exhaust pipe (21) | ||
20 | Unbolt and remove pressurized oil line (22) from turbocharger (20) and from crankcase | Installation: Install new sealing rings (22b). | |
21 | Unbolt connector for oil return flow line (24) at crankcase | Installation: Install new O-rings (25) and new gasket (24a). | |
22 | Unbolt support (30) of turbocharger to carrier of alternator | ||
23 | Slacken cylinder head bolts (2, 3) in stages, unscrew | Pay attention to slackening pattern in order to avoid damage caused by stresses. | |
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Installation: Tighten bolts according to tightening procedure. It is not necessary to retighten the cylinder head bolts (3). | |||
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24 | Remove cylinder head (1) | Installation: Inspect cylinder head gasket (16), replace. Pay attention to guide rails when fitting on cylinder head. Pay attention to dowel sleeves (15) for locating the cylinder head. | |
25 | Clean the separating surfaces, check for cracks and for flatness, clean the tapped holes | Visual inspection! | |
26 | Inspect cylinder walls for scores and signs of grooves | ||
Blow out threaded holes | Free of oil and water | ||
27 | Check cylinder head bolts (3) | ||
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28 | Install in the reverse order | ||
29 | Check engine for leaks | ||
30 | Inspecting cooling system for leaks | Do not pressure-test cooling system until engine has reached operating temperature as the cylinder head gasket is not watertight until the engine has reached operating temperature and the gasket has swollen. |
Check values for cylinder head bolts
Number | Designation | Engines | ||
BE01.30-N-1001-01A | Cylinder head bolt | Thread diameter | M | 10 |
Length (L) when new | mm | 80/ 102/ 115 | ||
Length (L) | mm | 82 / 104 / 117 | ||
See picture | ||||
Distributor injection pump
Number | Designation | Engine 602.980 | ||
BA07.13-N-1001-01A | Injection lines to injection nozzle/injection pump | Nm | 18 | |
Belt tensioning device
Oil pan
Number | Designation | Engine | ||
BA01.45-N-1012-01H | Bolt, oil dipstick guide tube to cylinder head | Nm | 9 | |
Exhaust system
Number | Designation | Engine | |
BA49.10-N-1002-01B | Flange connection for front exhaust system - turbocharger | Nm | 23 |
Cylinder head
Number | Designation | Engine 602.980 | |||
BA01.30-N-1002-01B | Cylinder head on crankcase | M10 | Stage 1 | Nm | 10 |
Stage 2 | Nm | 35 | |||
Stage 3 | ° | 90 | |||
Stage 4 | ° | 90 | |||
BA01.30-N-1003-01B | Cylinder head on timing case cover | M8 | Nm | 23 | |
601 589 00 10 00
Screwdriver bit
T hexagon socket wrench
116 589 03 07 00
605 589 00 33 00
Puller
Repair materials
Number | Designation | Order number |
BR00.45-Z-1012-01A | Omnifit FD 3041 sealant | A 002 989 47 20 10 |
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