Remove/install cylinder head

AR01.30-P-5800HD

Remove/install cylinder head

2.11.11

5.2.02

Value changed from 22 Nm to 20 Nm

Value in line BA07.16-P-1002-01A on engine 612.961/963 revised

*BA07.16-P-1002-01A

5.2.02

Value changed from 22 Nm to 20 Nm

Value in line BA07.16-P-1002-01A for engine 613.960/961ge modified

*BA07.16-P-1002-01A

5.2.02

Value changed from 22 Nm to 20 Nm

Value in row BA07.16-P-1002-01A changed for engine 611.962

*BA07.16-P-1002-01A

25.9.03

Value changed from 20 Nm to 23 Nm

Value modified in series 1002 for engine 613.960/961

*BA07.16-P-1002-01A

 

Remove/install

1

Disconnect battery ground line

Model 210

AR54.10-P-0003A

Model 220

AR54.10-P-0003I

2

Remove bottom section of soundproofing

Model 210

AR94.30-P-5300AB

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

3

Drain/fill in coolant

At radiator and crankcase.

AR20.00-P-1142HB



*BF20.00-P-1001-02E

4

Remove trim panels of the cylinder head cover (1, 2)

AR01.20-P-5014-02C



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

5

Remove air filter housing

AR09.10-P-1050C

6

Detach coolant hoses at coolant thermostat housing

 Inspect condition of hose clamps and hoses, replace if necessary.

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

7

Detach air intake hose (4/2) at turbocharger (110)

8

Detach vacuum hose (3) at turbocharger vacuum unit (110/10)

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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

9

Remove injectors (Y76)

AR07.16-P-1000HB

Impact extractor

*602589003300

Extraction claw

*611589003300

10

Clean injectors (Y76)

 Seal injector recesses with pin before cleaning.

Clean injector stems and injector recesses with fleece cloth.

Clean nozzle tips only with non-woven cloth.

Clean injector recesses with round and cylinder brush, blow out, clean with fleece cloth and cover up.

Clean injector stems with a wire brush and non-woven cloth and grease with special grease.

 Replace injector seal and screws of tensioning clamps.



Notes on injectors

Engines 611.960/961, 612.961, 613.960, 613.961, 668.940

AH07.16-P-1000-01A

Round brush

*611589006800

Cylinder brush

*668589006800

 Brake caliper brush

*000589266800

Special grease

*BR00.45-Z-1036-06A

11

Remove cylinder head cover (6)

AR01.20-P-5014HB

12

Position piston of cylinder 1 to ignition TDC

Rotate engine at crankshaft. Do not rotate engine at the Bolt, the camshaft sprocket. Do not rotate engine backwards.

13

Install retaining lock for crankshaft/starter ring gear

AR03.30-P-5000HB

14

Remove chain tensioner (4)

 Replace seal of chain tensioner (5).

AR05.10-P-7800HB

15

Remove front cover (7) at cylinder head

AR01.30-P-5700B

16

Remove top slide rail (8)

AR05.10-P-8432B

17

Remove camshafts (9, 10)

AR05.20-P-6992HB

18

Remove intermediate gear (24)

AR05.10-P-4650A

19

Remove camshaft housing (11)

20

Remove pressure line (19/1) at high pressure pump (19)



*BA07.16-P-1002-01A

21

Remove fuel return flow line between rail and high pressure pump

22

Remove high-pressure pump (19)

 Installation: Replace sealing ring.

AR07.02-P-1020HB

23

Separate electric plug connections at cylinder head

 At glow plugs, coolant temperature sensor, rail pressure sensor and pressure regulator valve. Separate attached cables and place to the side.

24

Remove exhaust heat exchanger (12)

25

Remove main fuel filter (70)

AR47.20-P-1070HB

26

Remove charge air manifold (110/1)

 Rail remains attached at cylinder head.

AR09.41-P-1310HD

27

Unbolt bracket (22, 23) at cylinder head

 At guide tube for engine oil and transmission oil dipstick.



*BA18.40-P-1001-01D

28

Disconnect primary catalytic converter (120/1) at turbocharger (110)

 Removal, installation: Detach primary catalytic converter at fixtures.

 Turbocharger and exhaust manifold remain attached at cylinder head.



*BA09.40-P-1002-01C

29

Detach charge air pipe (110/6) at turbocharger



*BA09.41-P-1002-01A

30

Remove oil return flow line (110/4) at turbocharger

 Installation: Install new gaskets.



*BA09.40-P-1003-01C

31

Take off bracket (13) at turbocharger



*BA09.40-P-1006-01C

32

Unscrew screw/bolt (14) of cylinder head at timing case cover

 Installation: Tightening procedure of screw/bolt (14) and (15) observe.



*BA01.30-P-1005-01A

33

Slacken cylinder head bolts (15) in stages, unscrew

 Slacken cylinder head bolts in reverse order of tightening procedure once engine has cooled down.

See 

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01HD

 Installation: Oil and insert cylinder head bolt at thread and bolt head contact surface. It is not necessary to retighten the cylinder head bolts.



*BA01.30-P-1007-01A

34

Check cylinder head bolts (15)

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

35

Remove cylinder head (16)

 Installation: Lay new cylinder head gasket (18) onto crankcase.

 When remounting the top, align with fitted bushings (20) for lining up the cylinder head.

 If the pistons/connecting rod have been replaced. See: 

Measure piston projection

AR03.10-P-7041-01B

Load regulator
gotis://H_00.12_04.0

36

Clean contact surfaces and threaded holes

 Blow out threaded holes, free of oil and water, inspect contact surfaces. See: 

Check/face-grind cylinder head contact surfaces

AR01.30-P-7162HB

37.1

Remove oil from cooling and heating system

If oil present in cooling and heating system.

AR20.00-P-1250B

38

Install in the reverse order

39

Inspect cooling system for leaks

 Engine with new cylinder head gasket:

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-P-1010HA

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

40

Check for oil leaks with engine running

 Danger!

Risk of explosion from 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-0001-01A

41

Check fuel system for leaks with engine running

42

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. See: 

STAR DIAGNOSIS

Number

Designation

Engine
613.960/961

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

Max. length (L)

mm

104

See picture

AR01.30-P-5800-03HB

Number

Designation

Engine 613.960/
961

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

Number

Designation

Engine 613.960/
961

BA01.30-P-1005-01A

Bolt, cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1007-01A

Bolt, cylinder head to crankcase M12

Stage 1

Nm

60

Stage 2

 °

90

Stage 3

 °

90

Number

Designation

Engine 613.960/
961

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

Number

Designation

Engine 613.960/
961

BA09.40-P-1002-01C

Connection of turbocharger to front catalytic converter

Nm

30

BA09.40-P-1003-01C

Bolt, oil drain line to turbocharger

Nm

9

BA09.40-P-1006-01C

Bolt, support to turbocharger

Nm

30

Number

Designation

Engine
611.960/961/962
612.961/962/963/967
613.960/961

BA09.41-P-1001-01A

Bolt to charge air manifold

M5

Nm

-

M7

Nm

16

BA09.41-P-1002-01A

Hose clamps for charge air pipes/hoses

Nm

3

BA09.41-P-1003-01A

Bolt on charge air cooler

Nm

-

BA09.41-P-1004-01A

Bolt of support to charge air manifold

Nm

20

BA09.41-P-1005-01A

Bolt of support to engine bracket

Nm

40

Number

Designation

Engine 613.960/
961

BA18.40-P-1001-01D

Bolt, dipstick guide tube to cylinder head

Nm

14

Number

Designation

Engine
613.960

Engine
613.961

BF20.00-P-1001-02E

Cooling system

Total filling capacity

Liters

15.5

11.2

Filling capacity of anticorrosion/
antifreeze down to -37°C

Liters

7.75

5.6

Filling capacity of anticorrosion/
antifreeze down to -45°C

Liters

8.0

6.2

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

BB00.40-P-0325-00A

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10