Remove/install cylinder head

AR01.30-P-5800MA

Remove/install cylinder head

2.11.11

 

Remove/install

1

Remove exhaust gas recirculation cooler

AR14.20-P-7665MA

2

Remove right and left cylinder head covers

AR01.20-P-5014M

3

Remove chain tensioner

AR05.10-P-7800MD

 Installation: When removing the chain tensioner, the location of the balancing shaft can change. In order to avoid an out-of-roundness engine run, the location of the balancing shaft must be checked after installing the chain tensioner: 

Check basic position of the balancing shaft

AR03.20-P-3637M

 Installation: Check basic position of camshafts.

AR05.20-P-6010M

Right cylinder head

4

Remove charge air intake pipe on right

AR09.41-P-1318M

5

Remove bottom charge air pipe on right

AR09.41-P-1315CD

6

Remove intermediate gear of high-pressure pump

AR05.10-P-4650MD

7

Remove right camshaft housing

AR05.20-P-6995M

8

Fully slacken right three way catalytic converter and push toward rear

9

Unplug electrical connector (1) at turbocharger

10

Detach oil return line (2) for right turbocharger

 Installation: Replace gasket and sealing ring.



*BA09.40-P-1002-01D

11

Detach bracket (3) of right turbocharger

 Bolt connecting support to turbocharger

*BA09.40-P-1006-01D

 Bolt connecting turbocharger support to crankcase

*BA09.40-P-1007-01D

Left cylinder head

12

Remove charge air intake pipe on left

AR09.41-P-1319M

13

Remove bottom charge air pipe on left

AR09.41-P-1316CD

14

Fully slacken left three way catalytic converter and push toward rear

15

Unplug electrical connector (1) at turbocharger

16

Detach oil return line (2) for left turbocharger

 Installation: Replace gasket and sealing ring.



*BA09.40-P-1002-01D

17

Detach bracket (3) of left turbocharger

 Bolt connecting support to turbocharger

*BA09.40-P-1006-01D

 Bolt connecting turbocharger support to crankcase

*BA09.40-P-1007-01D

18

Remove oil filter housing

AR18.20-P-3471M

19

Mark camshaft timing gear relative to timing chain

20

Detach and remove camshaft timing gear from exhaust camshaft

 Pay attention to dowel pin. Remove camshaft timing gear on fitted timing chain. Secure timing chain after removal of camshaft timing gear against falling down.



*BA05.10-P-1003-01A

21

Remove left camshaft housing

AR05.20-P-6995M

22

Remove slide rail pins (4)

 Impact extractor

*116589203300

Threaded stud

*116589013400

 Extractor

*605589003300

 Installation: Coat guide rail pins with sealant.

*BR00.45-Z-1009-01A

23

Tie slide rails (5) together to facilitate assembly of cylinder head

Both cylinder heads

24

Unplug electrical connectors at glow plugs

25

Remove screw/bolt (6) for cylinder head on crankcase



*BA01.30-P-1003-01H

26

Loosen cylinder head bolts (7) in stages and unscrew

 Loosen the cylinder head bolts when the engine has cooled off. To loosen them use the reverse order of the tightening procedure.

 Installation: Oil thread and contact surface of screw head.

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01M



*BA01.30-P-1003-01H

27

Check cylinder head bolts (7)

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

28

Remove cylinder head with engine hoist for better handling (8)

 Installation: Use new cylinder head gasket. While placing the cylinder head pay attention to the fitted sleeves for fixing the cylinder head in place. Fit on cylinder head with engine hoist for better handling (8).

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

29

Clean threaded holes of cylinder head bolts

 The tapped holes must not have any oil and water. Blow out the tapped holes.

30

Clean and check the separating surfaces at the cylinder head and the crankcase

31

Install in the reverse order

32.1

Remove oil from cooling and heating system

If oil present in cooling and heating system.

AR20.00-P-1250B

 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

33

Check for oil leaks with engine running

34

Inspect cooling system for leaks

 On new cylinder head gasket, only pressure check the cooling system if the engine has reached operating temperature; otherwise leakage could occur

AR20.00-P-1010HA

35

Connect STAR DIAGNOSIS and read fault memory



AD00.00-P-2000-04A

Number

Designation

Engine
628.960/961/
962/963

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

201.5

Max. length (L)

mm

203

See picture

AR01.30-P-5800-03HB

Number

Designation

Engine
628.960/961/962/
963

BA01.30-P-1003-01H

Bolt, cylinder head to crankcase

M12

Stage 1

Nm

20

Stage 2

Nm

60

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

M8

Nm

20

Number

Designation

Engine
628.960/963

BA05.10-P-1003-01A

Bolt, camshaft sprocket to exhaust camshaft

Nm

18

Number

Designation

Engine
628.962/
963

BA09.40-P-1002-01D

Bolt, oil drain line to turbocharger

Nm

9

BA09.40-P-1006-01D

Bolt, support to turbocharger

Nm

30

BA09.40-P-1007-01D

Bolt, turbocharger support to crankcase

Nm

-

Number

Designation

Order number

BR00.45-Z-1009-01A

Sealant Loctite 574, 50 ml

A 001 989 89 20 10