Remove/install cylinder head

AR01.30-S-5800B

Remove/install cylinder head

26.10.09

 

Remove/install



Remove cylinder head only once the engine has cooled off

1

Disconnect negative terminal on battery.

AR54.10-S-0005A

 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

2

Drain coolant

AP20.00-D-2080A

3

Remove intake manifold (13)

AR09.20-S-1310B

4

Remove injection nozzles (10)

AR07.03-S-6830A

5

Remove injection lines

AR07.12-S-9230A

6

Remove fuel heat exchanger (14)

for fuel heat exchanger (code M96)

AR47.21-S-5621A

7

Remove bolt and washer assemblies (11) and fuel filter (12) place with attached lines to one side



AR47.20-S-5510A

8

Remove poly-V belt

AP13.22-D-1381A

9

Remove spring clamp lever (3) and tensile spring (2)

 Installation position: Insert extension spring (2) with color-coding upwards

AR13.25-S-3200-01A

10

Remove bolt and washer assembly (1) for damper on cylinder head



*BA13.25-N-1003-01B

11

Remove vacuum lines (7) and (8) to the vacuum pump



*BA43.05-N-1002-01A

12

Remove support (5) for AC generator carrier

AR15.40-S-6232-01A



*BA01.40-N-1006-01B



*BA01.40-N-1007-01B

13

Remove camshaft (9)

AR05.20-S-6292A

14

Remove slide rail (6) in cylinder head

AR05.10-S-8432B

15

Disconnect electrical connections to the glow plug (R13-R16)



*BA15.20-N-1002-01A

16

Detach vacuum lines (24) and (25) on thermovalve (26)

Do not mix up the vacuum lines

17

Disconnect electrical connector (X42) for coolant temperature sensor (B8)

18

Remove coolant hose (15) and (16) on housing (17)

 Check condition of coolant hoses and hose clamps; replace if necessary

19

Detach coolant hose (29) from coolant line (28)

 Check condition of coolant hose and hose clamp; replace if necessary

20

Remove retainer (27) and coolant line (28) from the coolant outlet fitting

 Installation: Replace sealing ring on the coolant line, check condition of electrical fuse (27); replace if necessary

21

Detach coolant hose (21) to the heater return line (19)

 Check condition of coolant hose and hose clamp; replace if necessary

22

Remove bolt and washer assemblies (20)

 Installation: First fit all bolt and washer assemblies (20), then tighten



*BA20.20-N-1005-01B



*BA20.20-N-1006-01B

23

Remove heater return line (19) from the coolant pump housing and place to one side

 Installation: Replace sealing ring.



Observe assembly note for the exhaust system with corrugated hose!

 Do not load the exhaust pipe with corrugated hoses on the cable with the weight of the exhaust system; mount free of tension

AH49.10-N-0200-01A

24.1

Remove front exhaust system (22) on exhaust manifold

 Exhaust manifold remains on the cylinder head

AR49.10-S-7140B

24.2

Remove turbocharger (23)

Engine 601.970
 Exhaust manifold remains on the cylinder head

AR09.40-S-6020A

25

Remove Allen head bolts (31) to the timing case cover



*BA01.30-N-1003-01B

26

Release and remove cylinder head bolt (32, 33 and 34) in stages according to the loosening procedure

 Tightening, loosening procedure for cylinder head bolts

AR01.30-S-5800-01B



*601589001000



*BA01.30-N-1002-01B

 Installation: Lubricate cylinder head bolts on the head and on the contact surface

27

Check cylinder head bolts

and replace if necessary

AR01.30-S-5800-03B

*BE01.30-N-1001-01A

28

Take off cylinder head (30)

 Installation: Replace cylinder head gasket (35); observe fitting sleeves (36) for fixing the cylinder head (30)

29

Clean separating surfaces, check for cracks, clean the tapped holes

Free of oil and water

30

Install in the reverse order

31

Inspect cooling system for leaks

Do not pressure-test cooling system until engine has reached operating temperature.
The cylinder head gasket is not watertight until the engine has reached normal operating temperature and the gasket has swollen.

AR20.00-S-1010B

Number

Designation

Engine
601.942/943/970

BE01.30-N-1001-01A

Cylinder head bolt

Thread diameter

M

10

Length (L) when new

mm

80/ 102/ 115

Length (L)

mm

82 / 104 / 117

See picture

-

Number

Designation

Engine
601.942/
970

BA01.40-N-1006-01B

Supporting bracket to generator support

Nm

9

BA01.40-N-1007-01B

Supporting bracket to cylinder head

Nm

9

Number

Designation

Engine 601.942 601.970

BA01.30-N-1002-01B

Cylinder head on crankcase

M10

Stage 1

Nm

10

Stage 2

Nm

35

Stage 3

° 

90

Stage 4

° 

90

BA01.30-N-1003-01B

Cylinder head on timing case cover

M8

Nm

25

Number

Designation

Engine 601.942/
970

BA13.25-N-1003-01B

Shock absorber on cylinder head

Nm

21

Number

Designation

Engine 601.942 601.970

BA15.20-N-1002-01A

Nut, cable lug to glow plug

Nm

3.5

Number

Designation

Engine
601.942/
970

BA20.20-N-1005-01B

Heating return line to cylinder head

Nm

9

BA20.20-N-1006-01B

Heater return flow line and feed line
oil-water heat exchanger to crankcase

Nm

9

Number

Designation

Engine 601.942/
970

BA43.05-N-1002-01A

Vacuum line on vacuum pump

Nm

30