Remove/install cylinder head

AR01.30-P-5800TA

Remove/install cylinder head

14.2.12

 

Remove/install

 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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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

 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 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



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

1

Open engine hood

AR88.40-P-1000T

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Disconnect ground line of battery

 Insulate ground line to prevent unintentional contact between the detached ground line and battery ground point.



Notes on battery

All models

AH54.10-P-0001-01A

Model 211.0

AR54.10-P-0003T

Model 211.2

AR54.10-P-0003TA

3

Remove cylinder head cover trim

AR01.20-P-5014-02C

 Bolt, cylinder head cover trim to cylinder head

*BA01.20-P-1002-01G

 Bolt, cover to charge air manifold

*BA01.20-P-1003-01G

4

Remove air filter housing

AR09.10-P-1150T

5

Remove air intake pipe

AR09.10-P-8131T

6

Remove heat shield

AR49.00-P-1000-01T

7

Remove screw (9)

 Self-locking nut, three way catalytic converter to bracket

*BA49.10-P-1011-01I

8

Remove nuts (8)

 Nut connecting exhaust manifold to cylinder head

*BA14.10-P-1001-01A

9

Remove bracket (10)

10

Remove oil feed line (110/3) at turbocharger (110)

 Installation: Replace seals.

 Bolt, oil feed line to turbocharger

*BA09.40-P-1003-01E

 Bolt, oil feed line to cylinder head

*BA09.40-P-1004-01E

11

Remove bolts (2)

 Exhaust manifold remains attached at cylinder head.

 Flange connection, exhaust manifold to turbocharger

*BA09.40-P-1001-01E

12

Remove turbocharger (110)

13

Remove injectors

AR07.16-P-1000T

14

Remove rail

AR07.03-P-1010T

15

Disconnect electric cables for the removal of the cylinder head

AR01.30-P-5800-14T

16

Remove cylinder head cover

AR01.20-P-5014T

17

Remove bottom section of soundproofing

AR94.30-P-5300T

18

Remove screws (6) and take out oil dipstick guide tube (7)

19

Remove charge air duct to charge air cooler

AR09.50-P-8680T

20

Remove bracket (1)

21

Drain coolant at radiator

AR20.00-P-1142HB

22

Remove fan shroud

AR20.40-P-6800T

23

Disconnect fuel lines (14) at engine and place to one side

 Seal the connections.

Nut of pressure line to high pressure pump/rail

*BA07.16-P-1002-01D

 Clamping device

*000589403700

 Set of stop plugs

*129589009100

24

Disconnect coolant hose (3) at partition wall

25

Disconnect coolant hoses (5) from coolant thermostat

26

Remove camshafts

AR05.20-P-6992T

27

Remove camshaft housing

AR05.20-P-6995B

28

Remove intermediate gear of high-pressure pump

AR05.10-P-4650T

29

Remove bolt (18)

Bolt, cylinder head to timing case cover

*BA01.30-P-1001-01I

30

Loosen cylinder head bolts (19) in stages and unscrew

 To prevent stresses in cylinder head, loosen cylinder head bolts when engine has cooled off, in reverse order to tightening procedure.

AR01.30-P-5800-01TA

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

Bolt, cylinder head to crankcase M12

*BA01.30-P-1002-01I

31

Check cylinder head bolts (19)

AR01.30-P-5800-03T

32

Take cylinder (17) off crankcase

 Installation: Put new cylinder head gasket on crankcase. When fitting on, observe fitted sleeves for locating the cylinder head.

 Measure piston projection when replacing piston and connecting rod.

Engine hoist (self-locking)

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

33

Clean contact surfaces and threaded holes

 Blow out threaded holes and clean away any oil and water.

 Check contact surfaces and, if necessary:



Check/face-grind cylinder head contact surfaces

AR01.30-P-7162T

34.1

Remove oil from cooling and heating system

 In case of an oiled-up cooling and heating system.

AR20.00-P-1250B

35

Install in the reverse order

36

Inspecting cooling system for leaks

 Engine with new cylinder head gasket:

Pressure check the cooling system only after the engine has reached the operating temperature; otherwise leakage could occur.

AR20.00-P-1010HA

37

Check engine oil level

AR18.00-P-3035-01BD

38

Check for oil leaks with engine running

39

Check fuel system for leaks with engine running

40

Read out fault memory and erase

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine
648

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

Number

Designation

Engine
646.951/
961,
647.961, 648

BA07.16-P-1002-01D

Nut, pressure line to high-pressure pump/rail

Stage 1

Nm

23

Stage 2

Nm

-

Number

Designation

Engine
646.951/
961, 647, 648

BA09.40-P-1001-01E

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

30

Stage 2

°

-

BA09.40-P-1003-01E

Bolt, oil feed line to turbocharger

Nm

20

BA09.40-P-1004-01E

Bolt, oil feed line to cylinder head

Nm

9

Number

Designation

Engine
646.951/961/
962/963/966,
647.961,
648

BA01.30-P-1001-01I

Bolt, cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1002-01I

Bolt, cylinder head to crankcase M12

Stage 1

Nm

15

Stage 2

Nm

60

Stage 3

°

90

Stage 4

°

90

Number

Designation

Engine
646.951/961/
962/963/966,

Engine 647, 648

BA14.10-P-1001-01A

Nut to exhaust manifold at cylinder head

Nm

30

Number

Designation

Engine 648.961

BA49.10-P-1011-01I

Self-locking nut, catalytic converter to bracket

Nm

20