Remove/install cylinder head

AR01.30-I-5800B

Remove/install cylinder head

7.10.10

19.5.09

Value altered: peak-to-valley height (Rz) cylinder crankcase-contact surface

*BE01.40-N-1011-02B

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

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

AS00.00-Z-0002-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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 and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove soundproofing (1)

2

Drain coolant

 Catch coolant with a suitable container.



Replace coolant

AP20.00-I-2080B



Notes on coolant

AH20.00-N-2080-01A

3

Remove injection line (3)

AR07.15-I-9235B

4

Detach exhaust manifold (13) from cylinder head (18)

 Do not remove turbocharger from exhaust manifold.

AR14.10-I-3915B

5

Remove charge air manifold (2)

AR09.41-I-8681B

6

Detach constant throttle lines (14) from cylinder head (18)

7

Detach leak fuel line (16)
from cylinder head (18)

8

Remove coolant line (15)
on cylinder head (18)

9

Remove electrical engine wiring harness (11) to both coolant temperature sensors (B8)

10

Remove connection piece for coolant pump (8)

 Installation: The connection fitting (10) and seal (7) must be replaced.

AR20.10-W-1290-02A



*BA20.10-N-1003-01C

11

Remove rocker arm assembly (4)

AR05.00-I-5521B

12

Remove tappet rods (6)

 Installation: Ensure the push rods are correctly seated in the tappets.

13

Unscrew cylinder head bolts (17)

 Installation: Pay attention to tightening specifications for cylinder head bolts.

AR01.30-W-5800-07A



*BA01.30-N-1002-01C



*422589020900

14

Remove cylinder head (18) using lifting device (21)

 The cylinder head must be lifted carefully otherwise the installed nozzle holder assembly can be damaged.



*904589016300

15

Remove cylinder head gasket (19)

 Installation: Replace cylinder head gasket. Observe installation position of cylinder head gasket.

16

Seal thread, oil and coolant holes in crankcase with suitable plugs



Checking

17

Check shank length (L) of the
cylinder head bolts (17)

 Installation: If the maximum shank length (L) is exceeded the cylinder head bolt involved must be replaced.

*BE01.30-N-1001-01B

18

Check cylinder head (18) for cracks and other visible damage; replace if necessary

19

Check sealing surface on cylinder head (18); machine if necessary

Only when not replacing cylinder head.

AR01.30-I-7162B

20

Check cylinder crankcase contact surface; machine if necessary

 Inspect flatness of crankcase separating surface over the entire length and also diagonally

If a light gap is formed:

Check permissible deviation over the overall length using the feeler gauge.

*BE01.40-N-1013-02B

Check peak-to-valley height of the cylinder crankcase contact surface.

*BE01.40-N-1011-02B

If specified values are not achieved: 

Face-grind cylinder crankcase contact surface or replace cylinder crankcase.

 The cylinder crankcase must not go below the minimum height. Check marking of the crankcase height on the cylinder crankcase.

*BE01.40-N-1021-02B



Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A



Markings on cylinder crankcase

AH01.40-N-0001-02A

21

Install in the reverse order

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BE01.30-N-1001-01B

Cylinder head bolts

Thread

M

162

Length of shank when new

mm

149.0

Permissible shank length

mm

151.0

Number

Designation

Engine
904.9,
engine
906.9
without code MS8

BE01.40-N-1011-02B

Peak-to-valley height (Rz) of crankcase contact surface

μm

4 to 16

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0.030

over a length of 150 mm in longitudinal and transverse direction

mm

0.015

BE01.40-N-1021-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal dia.

Height standard 0

mm

298.33 to 298.40

Cylinder internal bore dia.code letter A

mm

101.985 to 101.991

Code letter B

mm

101.992 to 102.008

Code letter C

mm

102.009 to 102.015

Height deviation -0.3

mm

298.03 to 298.10

Cylinder bore internal dia.,
code letter A

mm

102.285 to 102.291

Code letter B

mm

102.292 to 102.308

Code letter C

mm

102.309 to 102.315

Height deviation -0.6

mm

297.73 to 297.80

Cylinder bore internal dia.,
code letter A

mm

102.585 to 102.591

Code letter B

mm

102.592 to 102.608

Code letter C

mm

102.609 to 102.615

Height deviation -0.9

mm

297.43 to 297.50

Cylinder internal bore dia.code letter A

mm

102.885 to 102.891

Code letter B

mm

102.892 to 102.908

Code letter C

mm

102.909 to 102.915

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA01.30-N-1002-01C

Cylinder head bolts on crankcase

Stage 1

Nm

20

Stage 2

Nm

70

Stage 3

Nm

170

Stage 4

Nm

280

Stage 5

°

90

Stage 6

°

90

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA20.10-N-1003-01C

Bolt, connection piece of coolant pump to cylinder head

Nm

50