Remove/install cylinder head

AR01.30-P-5800PP

Remove/install cylinder head

10.11.11

 

Remove/install

1

Disconnect battery ground line

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q

2

Remove bottom sections of soundproofing

AR94.30-P-5300P

 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 coolant

AR20.00-P-1142HB



*BF20.00-P-1001-02E

4

Separate electric plug connection at generator

5

Detach turbocharger (110) at bracket (13)



*BA09.40-P-1006-01C

6

Detach connectors on oil sensor

7

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

Engine 611

AR01.20-P-5014-02A

Engine 612

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

8

Remove air filter

AR09.10-P-1050C

9.1

Unbolt bracket (22) at cylinder head

 Transmission 722.6

10

Pull electrical connectors off the glow plugs, coolant temperature sensor, common rail pressure sensor and pressure regulator valve on cylinder head.

 Disconnect the attached cables and put them aside.

11

Unscrew ground cable on cylinder head

 Next to electrical cut-out valve (Y75).

12

Unscrew cable clamp on cylinder head

 For pressure regulating valve.

13

Remove thermostat housing (3)

AR20.10-P-2460PP

 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

14

Remove fuel injectors (Y76)

AR07.16-P-1000HB

Impact extractor

*602589003300

Extraction claw

*611589003300

15

Clean fuel injectors (Y76)

 Seal injector wells using a pin. Clean injector stems, injector recesses with fleece cloth. Clean nozzle tips only with non-woven cloth. Clean injector recesses with a round brush, cylinder brush, blow out and cover over. Clean injector stems with a wire brush and non-woven cloth and grease with special grease.

 Replace injector sealing ring and bolts of clamping claws, in order to avoid leakage.



Notes on injectors

Engine 611.960/961/962/981/987, 612.961/962/963/967/981/990, 613.960/ 961, 628.960, 668.940

AH07.16-P-1000-01A



Injector classification

Engine 611.960/ 961/ 962, 612.961/ 962/967/990

AH07.16-P-1001-01B

Round brush

*611589006800

Cylinder brush

*668589006800

 Brake caliper brush

*000589266800

Special grease

*BR00.45-Z-1036-06A

16

Remove cylinder head cover (6)

AR01.20-P-5014HB

17

Position piston of cylinder 1 to ignition TDC

 Rotate engine at crankshaft. Do not rotate engine at the screw/bolt of the camshaft sprocket. Do not crank engine back.
 Markings of camshaft/ camshaft bearing cap must be aligned.

18

Remove chain tensioner (4)

 Replace sealing ring (5) of chain tensioner to avoid leakage.

AR05.10-P-7800HB

19

Remove front cover (7) at cylinder head

AR01.30-P-5700B

20

Remove top slide rail (8)

AR05.10-P-8432B

21

Remove camshafts (9, 10)

AR05.20-P-6992HB

22

Remove camshaft housing (11)

23

Remove high-pressure pump (19)

Engine 611, 612 except engine 612.990

AR07.02-P-1020HB

Engine 612.990

AR07.02-P-1020PF

24

Remove intermediate gear (24)

AR05.10-P-4650A

25

Remove charge air manifold

AR09.41-P-1310PF

26

Remove oil feed line (110/3) at turbocharger

 Installation: Replace sealing rings to avoid leakage.



*BA09.40-P-1004-01C

27

Coolant line to coolant expansion reservoir

28

Detach primary catalytic converter (120/1) at crankcase

29

Unscrew the turbocharger (110) fastening bolts on the manifold

 Exhaust manifolds remain attached to cylinder head.



*BA09.40-P-1001-01C

30

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

 Installation: Tightening procedure of screw/bolts (14) and (15) observe.

 Engine 611.962

*BA01.30-P-1005-01A

 Engine 612.962/967/990

*BA01.30-P-1001-01M

31

Slacken cylinder head bolts (15) in stages, unscrew

 With the engine cooled down loosen cylinder head bolts in reverse order of tightening procedure: 

Cylinder head bolt tightening procedure for engine 611.962

AR01.30-P-5800-01HB

Cylinder head bolt tightening procedure for engine 612.962/967/990

AR01.30-P-5800-01HC

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

 Engine 611.962

*BA01.30-P-1007-01A

 Engine 612.962/967/990

*BA01.30-P-1003-01M

32

Check cylinder head bolts (15)

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

33

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 pistons/connecting rods have been replaced confer:

Measure piston projection

AR03.10-P-7041-01B

34

Clean contact surfaces and threaded holes

 Blow out threaded holes, free of any oil and water. Inspect contact surfaces, if necessary: 

Check/face-grind cylinder head contact surfaces

AR01.30-P-7162HB

35.1

Remove oil from cooling and heating system

If oil present in cooling and heating system.

AR20.00-P-1250B

36

Install in the reverse order

37

Inspect cooling system for leaks

 Engine with new cylinder head gasket:

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

38

Adjust engine oil to correct level



*BF18.00-P-1001-01A

 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

39

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

40

Check fuel system for leaks with engine running

41

Read out and erase fault memory using STAR DIAGNOSIS

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.

Number

Designation

Engine
611.962

Engine 612.962/967

Engine
612.990

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

12

12

Length (L) when new

mm

102

102

107

Max. length (L)

mm

104

104

-

See picture

AR01.30-P-5800-03HB

AR01.30-P-5800-03HB

AR01.30-P-5800-03HB

Number

Designation

Engine 611.960/
961/962

Engine 612.961/
962/967

Engine 612.990

BA01.20-P-1002-01A

Screw/bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

10

8

BA01.20-P-1003-01A

screw/bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

-

Number

Designation

Engine 611.962

BA01.30-P-1005-01A

Screw/bolt, cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1007-01A

Screw/bolt, cylinder head to crankcase M12

Stage 1

Nm

60

Stage 2

 °

90

Stage 3

 °

90

Number

Designation

Engine
612.961/962/963/965/966/967/981

Engine
612.990

BA01.30-P-1001-01M

Screw/bolt, cylinder head to timing case cover

M8

Nm

20

20

BA01.30-P-1003-01M

screw/bolt, cylinder head to crankcase M12

Stage 1

Nm

60

30

Stage 2

Nm

-

70

Stage 2

 °

90

-

Stage 3

 °

90

90

Stage 4

 °

-

90

Stage 5

 °

-

-

Number

Designation

Engine 611.962

Engine 612.962/
967

BA07.16-P-1002-01A

Nut, pressure line to high-pressure pump/rail

Nm

23

23

Number

Designation

Engine 611.962

Engine 612.962/
967

Engine 612.990

BA09.40-P-1001-01C

Flange connection, exhaust manifold to turbocharger

Nm

30

30

30

BA09.40-P-1004-01C

Oil feed line to turbocharger

Threaded fitting

Nm

30

30

-

Banjo bolt

Nm

18

18

18

BA09.40-P-1005-01C

Screw/bolt, oil feed line to cylinder head

Nm

9

9

-

BA09.40-P-1006-01C

Screw/bolt, support to turbocharger

Nm

30

30

30

Number

Designation

Engine
611.962 with ASSYST

Engine 612.962/967

Engine
612.990

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

6.5

6.5

6.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

BB00.40-P-0228-01A

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0229-01A

BB00.40-P-0229-01A

BB00.40-P-0229-01A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-03A

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Number

Designation

Engine
611.962

Engine
612.962/967

Engine
612.990

BF20.00-P-1001-02E

Cooling system

Total filling capacity

Liters

11.9

12.4

13.0

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

Liters

6.0

6.2

6.5

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

Liters

6.5

6.8

7.2

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

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