Remove/install cylinder head

AR01.30-G-5800DD

Remove/install cylinder head

04.12.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Shown on engine 926.9

1

Cylinder head

4

Bracket (only for engine brake)

7

Rocker arm assembly

2

Exhaust manifold

5

Valve fitting (only for engine brake)

10

Connection piece

3

Engine brake cylinder (only for engine brake)

Shown on engine 926.9

1

Cylinder head

12

Constant throttle line (only for engine brake)

14

Coolant line

11

Injection lines

13

Fuel return line

Shown on engine 926.9

1

Cylinder head

15

Holder (only for BlueTEC)

16

Cylinder head bolts

Shown on engine 926.9

1

Cylinder head

18

Electrical wiring harness

20

Lifting device

16

Cylinder head bolt

19

Coolant line connection fitting (only for BlueTEC)

L

Shank length

17

Bracket

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01B

 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 caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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 self-locking nuts and bolts

AH00.00-N-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

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on engine oil

AH18.00-N-0101-01HA

 

Remove/install

1

Drain coolant and capture in a suitable container

 See information from body manufacturer.

2

Remove charge air pipe from the exhaust gas turbocharger to the charge air cooler.

AR09.41-G-1331DD

3

Remove charge-air distributor.

AR09.41-G-8681DD

4

Remove rocker arm assembly (7).

AR05.00-G-5521DD

5

Remove connection piece (10) between the coolant pump and cylinder head (1).

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 926.9 in model 000.001

AR20.10-G-1290-02DE

Engine 925.9 in model 000.001

AR20.10-G-1290-02DD

 Installation: Install new seal and connection fitting.
Coat connection fittings with lubricant.

 Bolt, coolant pump connection piece to cylinder head

*BA20.10-N-1003-01L

Long-life grease

*BR00.45-Z-1001-06A

6

Remove engine brake cylinder (3).

Only for engine brake.

7

Release bracket (4) from the valve fitting (5) and swivel to one side.

Only for engine brake.

8

Remove exhaust manifold (2) from the cylinder head (1).

 Installation: Clean sealing surfaces and replace seals. The marking "TOP" must point on the seal towards the exhaust manifold (2).

 Bolt, exhaust manifold to cylinder head

*BA14.10-N-1001-01K

9

Remove constant throttle line (12) from the cylinder head (1).

Only for engine brake.

 Installation: Install new sealing rings.

10

Remove injection lines (11).

AR07.15-G-9235DD

 Installation: Check injection lines (11); replace if necessary.

11

Remove fuel return line (13) from the cylinder head (1).

 Installation: Install new sealing rings.

 Banjo bolt, fuel line to cylinder head

*BA07.15-N-1006-01D

12

Remove coolant line (14) from cylinder head (1).

 Installation: Install new sealing rings.

13

Remove bracket (15) from the cylinder head (1).

Only for BlueTEC.

14

Expose the electrical wiring harness (18).

15

Remove coolant line connection fitting (19) from the cylinder head (1).

Only for BlueTEC.

 Installation: Clean sealing surfaces and replace gasket.

16

Remove bracket (17) from the cylinder head (1).

 Installation: Mount holder screw/bolts for bracket (17) and the exhaust manifold (2) at the same time.

17

Remove cylinder head bolts (16).

Tightening specifications for cylinder head bolts

AR01.30-W-5800-07A

Cylinder head bolts

*BE01.30-N-1001-01I

 Cylinder head bolts on crankcase

*BA01.30-N-1002-01L

 Socket wrench bit

*422589020900

18

Lift off cylinder head (1) with the lifting device (20).


Set cylinder head (1) aside.
The install nozzle holder assembly will be damaged otherwise.

 The mounting eyes  for the lifting device (20) must point to the exhaust system.

 Lifting device

*904589016300

19

Remove cylinder head gasket.

 Installation: Install new cylinder head gasket. The marking "TOP" must point towards the cylinder head (1). Observe pilot bushing in crankcase.

20

Install in the reverse order.



Clean

21

Clean cylinder head (1) and check.

22

Close off all bores on crankcase contact surface using self-fabricated stop plugs.



Stop plugs for closing off bores

WF58.50-W-0100-04A

23

Clean crankcase contact surface.


No dirt may be allowed to find its way into the bores for engine oil, coolant, push rods and cylinder head bolts (16) as well as into the cylinder.
Engine damage can occur otherwise.



Check

24

Check cylinder head sealing surface and cylinder head gasket.

AR01.30-W-5800-15B

Permissible variation in flatness of lower separating surface in a longitudinal direction

*BE01.30-N-1002-02L

25

Measure shank length (L) of the cylinder head bolts (16).

Cylinder head bolts

*BE01.30-N-1001-01I

If the maximum shank length (L) is exceeded,



Replace corresponding cylinder head bolt (16).

26

Measure shank length of the exhaust manifold bolts.

Screw, exhaust manifold

*BE14.10-N-1001-01B

If the maximum shank length is exceeded,



Replace the respective exhaust manifold screw.

27

Perform additional inspection work after engine repair on the cylinder head (1) and on the cylinder head gasket.

AR01.10-G-0003DD

28

Remove all stop plugs.

29

Install in the reverse order

30

Start engine and perform an engine test run.

 See information from body manufacturer. Discharge approx. Allow engine to run in idle for approx. 10 s until the oil pressure has been built up; then, allow the engine to run at varying engine speeds.

31

Switch off engine and check area of the cylinder head (1) for leak tightness.

 Perform visual inspection.

32

Check/correct oil level.

 Engine oil

*BF18.00-N-1001-01Y

Check values for cylinder head bolts

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001

BE01.30-N-1001-01I

Cylinder head bolts

Thread diameter

M

16x2

Length of shank when new

mm

149,0

Permissible shank length

mm

151,0

Check values for cylinder head

Number

Designation

ENGINE 900.9, 904.9

ENGINE 902.9, 906.9

BE01.30-N-1002-02L

Permissible variation in flatness of lower separating surface in a longitudinal direction

over the entire length

mm

0,05

0,07

Over a length of 150 mm

mm

0,02

0,02

Check values for cylinder head

Number

Designation

ENGINE 924.9

Engine 925.9, 926.9 in model 000.001

BE01.30-N-1002-02L

Permissible variation in flatness of lower separating surface in a longitudinal direction

over the entire length

mm

0,05

0,07

Over a length of 150 mm

mm

0,02

0,02

Check values for exhaust manifold

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001

BE14.10-N-1001-01B

Screw, exhaust manifold

Thread diameter

M

10

Length of shank when new

mm

47,0

Permissible shank length

mm

47,5

 Cylinder head

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 (except 906.901/902) in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA01.30-N-1002-01L

Cylinder head bolts on crankcase

Stage 1

Nm

20

20

Stage 2

Nm

70

70

Stage 3

Nm

170

170

Stage 4

Nm

280

280

Stage 5

°

90

90

Stage 6

°

90

90

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 900.9, 902.9 (except 902.90), 904.9, 906.9 (except 906.90) in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA07.15-N-1006-01D

Banjo bolt, fuel line to cylinder head

Nm

50

50

 Exhaust manifold

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BA14.10-N-1001-01K

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

10

Stage 2

Nm

55

55

Stage 3

°

90

90

 Coolant pump, coolant thermostat

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA20.10-N-1003-01L

Bolt, coolant pump connection piece to cylinder head

Nm

50

50

 Engine lubrication

Number

Designation

Engine 900.9 in model 000.001

Engine 902.9 in model 000.001

BF18.00-N-1001-01Y

Engine oil

Filling capacity with oil filter

Liter

15,8

29,0

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

-

-

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 904.9 in model 000.001

Engine 906.9 in model 000.001

BF18.00-N-1001-01Y

Engine oil

Filling capacity with oil filter

Liter

15,8

29,0

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 924.9 in model 000.001

Engine 925.9 in model 000.001

BF18.00-N-1001-01Y

Engine oil

Filling capacity with oil filter

Liter

15,8

29,0

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

-

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 926.9 in model 000.001

BF18.00-N-1001-01Y

Engine oil

Filling capacity with oil filter

Liter

29,0

Sheet

BB00.40-P-0228-05A

Sheet

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-31A

Sheet

BB00.40-P-0228-51A

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11