Remove/install cylinder head

AR01.30-G-5800MT

Remove/install cylinder head

29.05.2012

ENGINE

444.901 in MODEL 000.001

Euro 1

ENGINE

444.901 in MODEL 000.001

Euro 2

ENGINE

447.903 in MODEL 000.001

Euro 2

Modification notes

07.06.2006

Cylinder head, protrusion of injection nozzles in cylinder head

BE01.30-N-1001-02P

30.10.2006

Cylinder head bolt, max. shank length.

BE01.30-N-1001-01N

1

Screw/bolt

2

Spring washer

3

Cylinder head cover

4

Seal

5

Tappet rod

6

Seal

7

Cylinder head

8

Seal

9

Seal

10

Cylinder head bolt (short)

11

Cylinder head bolt (mid-size)

12

Cylinder head bolt (long)



Remove

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger !

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

 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



Notes on coolant

AH20.00-N-2080-01A

1

Completely drain coolant from engine

 See MTU operator's manual.

2.1

Remove turbocharger

Engine 4447.903

 See MTU workshop manual.

2.2

Remove turbocharger

Engine 444.901

Only perform if cylinder head (7) to be removed is in area of the rear exhaust manifold.



Remove/install right turbocharger

AR09.40-G-6027MTA

Remove/install left turbocharger

AR09.40-G-6026MTA

3.1

Remove exhaust manifold

Engine 447.903

 See MTU workshop manual.

3.2

Remove exhaust manifold

Engine 444.901

AR14.10-G-3915MTA

4

Remove intake manifold

Engine 447.903

AR09.20-G-1310MT

5

Detach injection lines

AR07.11-G-9230MT

6

Remove charge air manifold

Engine 444.901

AR09.41-G-8681MTA

7

Detach leak oil line from nozzle holder

8

Remove cylinder head cover (3)

AR01.20-G-5014MT

9

Remove rocker arm bracket (13)

10

Pull push rods (5) out of crankcase

11

Loosen and remove cylinder head bolts (10, 11, 12)

 The cylinder head bolt (10) below the nozzle holder can only be slackened using a special wrench.
The cylinder head bolt (10) cannot be removed completely from the cylinder head (7).

 Box wrench bit

*403589020300

12

Remove cylinder head (7)

AR01.30-G-5800-11MT

13

Clean all parts and inspect for wear



Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

 Remove threaded holes in cylinder crankcase, face of the cylinder head (7), face of the cylinder crankcase and water residues.



Check

14

Check separating surface on crankcase for damage and corrosion



Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

 If there is a complaint, face-grind separating surface on crankcase.

15

Inspect flatness of cylinder head (7)

AR01.30-G-5800-12MT

 If there is a complaint, face-grind cylinder head (7).

Cylinder head

*BE01.30-N-1001-02P

Lower separating surface of cylinder head

*BE01.30-N-1002-02P

16

Inspect flatness of crankcase separating surface

 BE01.40-N-1005-02O and BE01.40-N-1006-02O are still missing in this operation step since they have not been migrated yet!!!

 It must not be possible to insert the feeler gage between crankcase contact surface and knife-edge straightedge. If inspection is carried out in the transverse direction, the permissible variation stated is merely a reference value and cannot be measured.

 If there is a complaint, face-grind separating surface on crankcase.

Crankcase - flatness of separating surface

*BE01.40-N-1006-02O

Peak-to-valley height (Rz) cylinder crankcase

*BE01.40-N-1005-02O

Inspect flatness of crankcase separating surface using a straightedge over the entire length and also diagonally. If a light gap forms:



Check permissible variation with the feeler gage.



Install

17

Fit cylinder head (7) onto crankcase

AR01.30-G-5800-11MT

18

Tighten cylinder head bolts (10, 11, 12) as specified in tightening pattern

Tightening specifications for cylinder head bolts

AR01.30-G-5800-07MT

 Lightly lubricate cylinder head bolts (10, 11, 12). Use a box wrench bit for cylinder head bolt (10) under the nozzle holder. Observe tightening instructions and tightening procedure.

Cylinder head bolt

*BE01.30-N-1001-01N

 Cylinder head bolt to crankcase

*BA01.30-N-1001-01P

 Torque wrench

*000589642100

 Torque wrench

*000589392100

 Wrench socket

*422589010900

 Box wrench bit

*403589020300

19

Install push rods (5)

 Lubricate push rods (5) on contact areas.

20

Fit on rocker arm bracket (13) and slightly tighten bolts (14)

 Align rocker arms to valves.

21

Tighten screw/bolts (14) for rocker arm bracket (13)

 Bolt, rocker arm bracket to cylinder head

*BA05.00-N-1001-01L

 Torque wrench

*000589642100

22

Set valve clearance



Set valve clearance

AP05.30-G-0560MT

23

Install cylinder head cover (3)

AR01.20-G-5014MT

 Install new seal (4).

24

Install charge air manifold

Engine 444.901

AR09.41-G-8681MTA

25

Connect up injection lines

AR07.11-G-9230MT

26

Plug in leak oil lines onto nozzle holders

27

Install intake manifold

Engine 447.903

AR09.20-G-1310MT

28.1

Install exhaust manifold

Engine 447.903

 See MTU workshop manual.

28.2

Install exhaust manifold

Engine 444.901

AR14.10-G-3915MTA

29.1

Install turbocharger

Engine 447.903

 See MTU workshop manual.

29.2

Install turbocharger

Engine 444.901

Remove/install right turbocharger

AR09.40-G-6027MTA

Remove/install left turbocharger

AR09.40-G-6026MTA

 Only perform if a turbocharger was removed.

30

Pour in coolant

 See MTU operator's manual.

31

Bleed fuel system

 See MTU workshop manual.

Test and adjustment values for crankcase

Number

Designation

ENGINE 444.901

ENGINE 447.903

BE01.40-N-1006-02O

Crankcase - flatness of separating surface

over the entire length

mm

0,030

0,030

Over a length of 150 mm in longitudinal and transverse direction

mm

0,015

0,015

Check values for cylinder head bolts

Number

Designation

ENGINE 444.901, 447.903

BE01.30-N-1001-01N

Cylinder head bolt

M152

Max. shank length

mm

111

Max. shank length

mm

146

Max. shank length

mm

170

Check values for cylinder head

Number

Designation

ENGINE 444.901, 447.903

BE01.30-N-1002-02P

Lower separating surface of cylinder head

Peak-to-valley height (Rz)

mm

0...0,016

Check values for cylinder head

Number

Designation

ENGINE 444.901, 447.903

BE01.30-N-1001-02P

Cylinder head

Overall height

mm

113,9...114

Minimum height

mm

113,3

permissible unevenness of lower separating surface over a length of 150 mm

mm

0,015

Permissible deviation of upper to lower separating surface

mm

0,2

Protrusion of injection nozzles in cylinder head

mm

0,82...1,57

Test and adjustment values for crankcase

Number

Designation

ENGINE 444.901

ENGINE 447.903

BE01.40-N-1005-02O

Peak-to-valley height (Rz) cylinder crankcase

Upper separating surface

mm

0...0,016

0...0,016

Lower separating surface

mm

0...0,016

0...0,016

 Cylinder head

Number

Designation

ENGINE 444.901

ENGINE 447.903

BA01.30-N-1001-01P

Cylinder head bolt to crankcase

Stage 1

Nm

10

10

Stage 2

Nm

50

50

Stage 3

Nm

100

100

Stage 4

Nm

145

145

Stage 5

Nm

180

180

Stage 6

°

120

95

 Engine timing - general

Number

Designation

ENGINE 444.901, 447.903

BA05.00-N-1001-01L

Bolt, rocker arm bracket to cylinder head

Nm

75