Remove/install cylinder head · ar0130g5800ch · Mercedes-Benz WIS

AR01.30-G-5800CH

Remove/install cylinder head

06.03.2020

Engine

457.9, 458.9 in model 000.001

Modification notes

14.06.2018	Permissible deviation in flatness of lower contact surface in longitudinal direction		BE01.30-N-1002-02N
17.06.2018	Work procedure completely revised.

1	Cylinder head
2	Constant throttle line
3	Constant throttle line
4	Coolant bleed line
5	Cylinder head bolt
6	Rocker arm assembly
7	Valve bridge
8	Leak fuel line
9	Push rod
10	Cylinder head seal
11	Pilot bushing
L	Shank length

W01.30-1058-06

Shown on engine 457.9 with BlueTEC

2	Constant throttle line
12	Clip
13	Screw
14	Clamp (only for engines with BlueTEC)
15	Compressed-air line (only for engines with BlueTEC)
16	Coolant line (only for engines with BlueTEC)
17	Lifting eye at the rear
A	Angles

G01.30-3154-11

 Danger	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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 containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
 Caution	Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
Topical note	Information on working sealing surfaces when carrying out engine repairs		AH01.10-N-0002-01A
	Remove
1	Drain off coolant.	 See information from body manufacturer.
2	Switch off ignition.
3	Remove exhaust manifold.	Without turbobrake.	AR14.10-G-3006CH
		With turbobrake.	AR14.10-G-3006CHA
4	Remove coolant bleed line (4) at all cylinder heads (1) and tie to one side.
5	Remove clamp (12) of constant throttle line (2) at rear lifting eye (17).
6	Remove constant throttle line (2) at connection fitting.
7	Remove clamp (14) of compressed-air line (15) and coolant line (16) at rear lifting eye (17).	Only for BlueTEC. Only at cylinder head (1) of cylinder 6 .
8	Release screws (13) and push rear lifting eye (17) away from cylinder head (1) until angle piece (A) is no longer in contact with cylinder head (1).	Only for BlueTEC. Only at cylinder head (1) of cylinder 6 .
		 Do not bend and/or damage lines attached to rear lifting eye (17).
9	Remove constant throttle line (3) at all cylinder heads (1).
10	Remove charge-air distributor.		AR09.41-G-8681CH
11	Remove injection line at affected cylinder head (1).		AR07.15-G-8971CH
12	Remove leak fuel line (8) at affected cylinder head (1).	 In addition, remove leak fuel line (8) at cylinder heads (1) located in front of and behind affected cylinder head and push away leak fuel line (8).
13	Remove cylinder head cover at affected cylinder head (1).		AR01.20-G-5014CH
14	Remove rocker arm assembly (6) at affected cylinder head (1).		AR05.00-G-5521CH
15	Remove valve bridges (7).
16	Remove pushrods (9).
17	Remove cylinder head bolts (5).	 Wrench socket	*422589010900
18	Remove cylinder head (1) and set aside.	 Always set aside cylinder head (1). Installed nozzle holder assembly will otherwise be damaged.
19	Remove cylinder head gasket (10) from crankcase.
	Clean
20	Seal all bores at crankcase sealing surface with self-fabricated stop plugs.
	Stop plugs for closing off bores		WF58.50-W-0100-04A
21	Clean sealing surfaces at exhaust manifold.
22	Clean contact surface of cylinder head (1) using high-performance disc.	 Rinse bores of cylinder head (1) after cleaning with brake cleaner and then blow out well with compressed air. Otherwise there will be engine damage/bearing damage shortly after the repair.
		 Clean only with a scraper or high-performance bristle disc.
		Assembly cleaner	*BR00.45-Z-1028-04A
		3M Bristle DiscTM high-performance disc Ø 115 mm, color white (fine), art. no.: 24539	*BR00.45-Z-1074-04A
23	Clean crankcase sealing surface and cylinder head sealing surface.	 Clean only with a scraper or high-performance bristle disc.
		3M Bristle DiscTM high-performance disc Ø 115 mm, color white (fine), art. no.: 24539	*BR00.45-Z-1074-04A
24	Carefully remove self-fabricated stop plugs from all crankcase bores.
25	Rinse all bores in cylinder head (1) with cleaner and blow out with compressed air.	Assembly cleaner	*BR00.45-Z-1028-04A
26	Blow out all threaded holes of cylinder head bolts (5) in crankcase with compressed air.
	Check
27	Check oil scraper ring in cylinder liner for carbonization.	Only if installed.
		If significant carbonization is present,
		
		remove oil scraper ring, remove carbonization and reinstall oil scraper ring.
28	Check cylinder head sealing surface and cylinder head gasket (10).		AR01.30-G-5800-15CH
		Height of cylinder head	*BE01.30-N-1001-02N
		Permissible deviation in flatness of lower contact surface in longitudinal direction	*BE01.30-N-1002-02N
29	Check crankcase sealing surface for damage.	If damage exists,
		
		Replace crankcase.
30	Check cylinder head bolts (5) for damage and measure shank length (L).		AR01.30-G-5800-03CH
		Cylinder head bolts M152	*BE01.30-N-1001-01M
31	Check pushrods (9) for deformation and damage.	 Visual inspection.
		If deformation or damage is present at socket or at ball head,
		
		replace corresponding pushrod (9).
	Install
32	Mount new cylinder head gasket (10) over pilot bushings (11) on crankcase sealing surface.	 Observe installation position of cylinder head gasket (10).
33	Mount cylinder head (1) over pilot bushings (11) on cylinder head gasket (10).
34	Wet contact surface, thread and shank of cylinder head bolts (5) with clean engine oil.
35	Tighten cylinder head bolts (5) at cylinder head (1).		AR01.30-G-5800-07CH
		 Observe tightening specifications for cylinder head bolts (5).
		 Cylinder head bolt on crankcase	*BA01.30-N-1001-01O
		 Wrench socket	*422589010900
36	Wet pushrods (9) with clean engine oil and install.	 Observe seat of pushrods (9) in roller tappets.
37	Insert valve bridges (7).
38	Install rocker arm assembly (6) at cylinder head (1).		AR05.00-G-5521CH
39	Install cylinder head cover at cylinder head (1).		AR01.20-G-5014CH
40	Attach leak fuel line (8) at cylinder head (1).	 Install new sealing rings.
		 Leak oil line for fuel on cylinder head	*BA01.30-N-1005-01O
41	Install injection line at cylinder head (1).		AR07.15-G-8971CH
42	Install charge-air distributor.		AR09.41-G-8681CH
43	Install constant throttle line (3) at all cylinder heads (1).	 Install new sealing rings.
		 Compressed air line for constant throttle on cylinder head	*BA01.30-N-1004-01O
44	Tighten screws (13) at rear lifting eye (17).	Only for BlueTEC. Only at cylinder head (1) of cylinder 6 .
		 Do not bend and/or damage lines attached to rear lifting eye (17).
		 Bolt, rear engine suspension lug to crankcase	*BA22.10-N-1006-01V
45	Install clamp (14) of compressed-air line (15) and coolant line (16) at rear lifting eye (17).	Only for BlueTEC. Only at cylinder head (1) of cylinder 6 .
		 Bolt, clamp to rear engine suspension lug	*BA22.10-N-1008-01V
46	Install constant throttle line (2) at connection fitting.
47	Install clamp (12) of constant throttle line (2) at rear lifting eye (17).	 Bolt, clamp to rear engine suspension lug	*BA22.10-N-1008-01V
48	Install coolant bleed line (4) at all cylinder heads (1).	 Connection fitting, coolant vent line to cylinder head	*BA01.30-N-1002-01O
		 Banjo bolt, coolant vent line to connection fitting	*BA01.30-N-1003-01O
49	Install exhaust manifold.	Without turbobrake.	AR14.10-G-3006CH
		With turbobrake.	AR14.10-G-3006CHA
50	Perform additional inspection work after engine repair at cylinder head (1) and at cylinder head gasket (10).		AR01.10-G-0003CH
51	Fill in coolant.
	Coolant specifications		BB00.40-P-0310-01A
		 See information from body manufacturer.
52	Start engine and allow to run in idle for about 10 s until the oil pressure has built up, then run the engine at varying speeds.	If engine fails to start or only runs for a brief period,
		
		Bleed fuel system.
			AR47.00-G-1720CI
53	Switch off engine and check area of the cylinder head (1) for leak tightness.	 Visual inspection.
54	Check and correct engine oil level.	 Check engine oil level after waiting at least 5 min. after switching off the engine.
		 Engine oil	*BF18.00-N-1001-01K

Check values for cylinder head bolts

Number	Designation			Engine 457.9, 458.9, 541.9, 542.9, 941.9, 942.9
BE01.30-N-1001-01M	Cylinder head bolts M152	Length of shank when new	mm	210
		Permissible shank length	mm	212

Check values for cylinder head

Number	Designation			Engine 457.9, 458.9, 541.9, 542.9, 941.9, 942.9 in model 000.001 without inductive hardening on cylinder head	Engine 457.9, 458.9, 541.9, 542.9, 941.9, 942.9 in model 000.001 with inductive hardening on cylinder head
BE01.30-N-1001-02N	Height of cylinder head	New	mm	113,85...114,15	113,85...114,15
		after stock removal	mm	113,5	–

Check values for cylinder head

Number	Designation		Engine 457.9, 458.9, 541.9, 542.9, 941.9, 942.9 in model 000.001 without inductive hardening on cylinder head	Engine 457.9, 458.9, 541.9, 542.9, 941.9, 942.9 in model 000.001 with inductive hardening on cylinder head
BE01.30-N-1002-02N	Permissible deviation in flatness of lower contact surface in longitudinal direction	mm	0,1	0,1

 Cylinder head

Number	Designation			ENGINE 457.9, 458.9
BA01.30-N-1001-01O	Cylinder head bolt on crankcase	Stage 1	Nm	10
		Stage 2	Nm	50
		Stage 3	Nm	100
		Stage 4	Nm	200
		Stage 5	°	90
		Stage 6	°	90

 Cylinder head

Number	Designation		ENGINE 457.9, 458.9
BA01.30-N-1002-01O	Connection fitting, coolant vent line to cylinder head	Nm	35

 Cylinder head

Number	Designation		ENGINE 457.9, 458.9
BA01.30-N-1003-01O	Banjo bolt, coolant vent line to connection fitting	Nm	35

 Cylinder head

Number	Designation		ENGINE 457.9, 458.9
BA01.30-N-1004-01O	Compressed air line for constant throttle on cylinder head	Nm	45

 Cylinder head

Number	Designation		ENGINE 457.9, 458.9
BA01.30-N-1005-01O	Leak oil line for fuel on cylinder head	Nm	15

 Engine mounts, engine supports

Number	Designation		ENGINE 457.9, 458.9
BA22.10-N-1006-01V	Bolt, rear engine suspension lug to crankcase	Nm	200

 Engine mounts, engine supports

Number	Designation		ENGINE 457.9, 458.9
BA22.10-N-1008-01V	Bolt, clamp to rear engine suspension lug	Nm	25

 Engine lubrication

Number	Designation			Engine 457.9, installation position horizontal	Engine 457.9, installation position vertical, used as bus engine except engine 457.944/953/96
BF18.00-N-1001-01K	Engine oil	Filling capacity with oil filter	Liter	32	29,5
		sheet		BB00.40-P-0228-05A	BB00.40-P-0228-05A
		sheet		BB00.40-P-0228-03A	BB00.40-P-0228-03A
		sheet		BB00.40-P-0228-01A	BB00.40-P-0228-01A
		sheet		BB00.40-P-0228-31A	BB00.40-P-0228-31A
		sheet		BB00.40-P-0228-51A	BB00.40-P-0228-51A

 Engine lubrication

Number	Designation			Engine 457.944/953/96, installation position vertical, used as bus engine	Engine 457.9, installation position vertical, all applications except bus engine
BF18.00-N-1001-01K	Engine oil	Filling capacity with oil filter	Liter	32	39
		sheet		BB00.40-P-0228-05A	BB00.40-P-0228-05A
		sheet		BB00.40-P-0228-03A	BB00.40-P-0228-03A
		sheet		BB00.40-P-0228-01A	BB00.40-P-0228-01A
		sheet		BB00.40-P-0228-31A	BB00.40-P-0228-31A
		sheet		BB00.40-P-0228-51A	BB00.40-P-0228-51A

 Engine lubrication

Number	Designation			ENGINE 458.9 with rear sump oil pan with firewall height 330 mm	ENGINE 458.97/98 except rear sump oil pan with firewall height 330 mm
BF18.00-N-1001-01K	Engine oil	Filling capacity with oil filter	Liter	43	29,5
		sheet		BB00.40-P-0228-05A	BB00.40-P-0228-05A
		sheet		BB00.40-P-0228-03A	BB00.40-P-0228-03A
		sheet		BB00.40-P-0228-01A	BB00.40-P-0228-01A
		sheet		BB00.40-P-0228-31A	BB00.40-P-0228-31A
		sheet		BB00.40-P-0228-51A	BB00.40-P-0228-51A

 Engine lubrication

Number	Designation			ENGINE 458.99 with rear sump oil pan with firewall height 235 mm	ENGINE 458.99 with front sump oil pan
BF18.00-N-1001-01K	Engine oil	Filling capacity with oil filter	Liter	32	39
		sheet		BB00.40-P-0228-05A	BB00.40-P-0228-05A
		sheet		BB00.40-P-0228-03A	BB00.40-P-0228-03A
		sheet		BB00.40-P-0228-01A	BB00.40-P-0228-01A
		sheet		BB00.40-P-0228-31A	BB00.40-P-0228-31A
		sheet		BB00.40-P-0228-51A	BB00.40-P-0228-51A

422 589 01 09 00

Wrench socket

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01
BR00.45-Z-1074-04A	3M Bristle DiscTM high-performance disc Ø 115 mm, color white (fine), art. no.: 24539	3MDeutschland GmbH Carl-Schurz-Strasse 1 41453 Neuss Germany Tel. +49 2131 14-0 Fax +49 2131 14-2649 http://www.3M.com

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