Remove/install cylinder head · ar0130d5800s · Mercedes-Benz WIS

AR01.30-D-5800S

Remove/install cylinder head

18.12.09

ENGINES 602.984 in MODEL 667, 668, 670

ENGINES 602.985 in MODEL 668, 670

D01.30-0060-09

D01.30-0061-09

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

22 Pressure oil line

22 A Banjo bolt

22b Sealing ring

23 Chain tensioner with sealing ring

24 Connection, oil return flow line to crankcase

24 A Gasket

25 O-ring

26 Oil return line

27 Camshaft

31 Exhaust pipe

32 Oil-coolant heat exchanger

 	Remove/install
1	Disconnect ground cable from battery
2	Remove viscous fan clutch		AR20.40-D-5660B
3	Unscrew air compressor intake air hose from air filter housing	Engine 602.985
4	Take off fixture of injection lines (13)
5	Detach leak oil lines (11)
6	Remove injection line (12)		*BA07.13-N-1001-01A
7	Remove alternator	Engine 602.985	AR15.40-D-5032A
8	Remove intake manifold		AR09.20-D-1310A
9	Unplug electrical connections at the cylinder head		AR01.30-D-5800-08A
10	Remove fuel filter (4)	 Engine 602.984: Place fuel filter to the side with lines connected and attach to the vehicle
11	Remove camshaft		AR05.20-D-6292A
12	Slacken poly-V-belt, remove	 Installation: Hexagon bolt for attaching tensioning lever must be inserted into the cylinder head before installing the intake manifold	AP13.22-D-1381-01B
13	Unbolt dipstick guide tube at cylinder head (18)		*BA01.45-N-1012-01H
14	Unscrew bolt (17) of shock absorber of poly-V-belt tensioning device to cylinder head		*BA13.25-N-1003-01B
15	Remove oil-coolant heat exchanger (32)		AR18.30-D-6840B
16	Detach coolant hoses (9, 10) at cylinder head
17	Remove coolant pipe at cylinder head
18	Remove charge air hose (28) on turbocharger (20).		*BA49.10-N-1002-01B
19	Unbolt exhaust pipe (31) from turbocharger (20)	  Installation: Install new nuts	*BA49.10-N-1002-01B
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	Unscrew bracket for charge air hoses on cylinder head	Engine 602.985  Only when replacing the cylinder head
23	Pull out guide rail pins in cylinder head		AR01.30-D-5800-04B
			*116589203300
			*116589013400
			*605589003300
		 Installation: Apply sealant to the slide rail pins	*BR00.45-Z-1012-01A
24	Slacken cylinder head bolts (2, 3) in stages, unscrew	 Pay attention to slackening diagram	AR01.30-D-5800-09A
			*601589001000
		 Installation:  Tighten bolts according to tightening procedure. It is not necessary to retighten the cylinder head bolts (3)	AR01.30-D-5800-01A
			*116589030700
			*BA01.30-N-1002-01B
			*BA01.30-N-1003-01B
25	Remove cylinder head (1)	 Installation: Inspect cylinder head gasket (16), replace.  When fitting on cylinder head, pay attention to guide rails; tie guide rails together, if necessary.  Pay attention to dowel sleeves (15) for locating the cylinder head.
26	Clean the separating surfaces, check for cracks and for flatness, clean the tapped holes	 Blow out tapped holes free of oil and water
27	Inspect cylinder walls for scores and signs of grooves
28	Inspect cylinder head bolts (2, 3)		AR01.30-D-5800-03A
			*BE01.30-N-1001-01A
29	Install in the reverse order
30	Run engine and check for leaks
31	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.	AR20.00-D-1010A

Check values for cylinder head bolts

Number	Designation			Engines 602.980/984/985


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		AR01.30-P-5800-03HA

Distributor injection pump

Number	Designation		Engine 602.984/ 985


BA07.13-N-1001-01A	Injection lines to injection nozzle/injection pump	Nm	18

Belt tensioning device

Number	Designation		Engine 602.984/ 985


BA13.25-N-1003-01B	Shock absorber on cylinder head	Nm	23

Oil pan

Number	Designation		Engine 602.984/ 985


BA01.45-N-1012-01H	Bolt, oil dipstick guide tube to cylinder head	Nm	9

Exhaust system

Number	Designation		Engine 602.984/ 985


BA49.10-N-1002-01B	Flange connection for front exhaust system - turbocharger	Nm	25

 Cylinder head

Number	Designation				Engine 602.984/ 985


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