Remove/install compressor cylinder head · ar1330g6010b · Mercedes-Benz WIS

AR13.30-G-6010B

Remove/install compressor cylinder head

25.10.2018

Engine

900.915/916/920/921, 902.923/924/935, 904.927/928/952/953, 906.935/955, 924.916/923/931

Shown on the compressor (1) with 352 cm3 displacement

1	Compressor
2	Cylinder head
3	Coolant line
4.1	Elbow fitting
4.2	Threaded fitting
5	Compressed-air line
6	Coolant line
7	Control line
8.1	Ball
8.2	Union nut
B16	Cylinder 1 TDC sensor

G13.30-3127-06

Shown on the compressor (1) with 393 cm3 displacement

1	Compressor
2	Cylinder head
3	Coolant line
4.1	Elbow fitting
4.2	Threaded fitting
5	Compressed-air line
6	Coolant line
B16	Cylinder 1 TDC sensor

G13.30-3135-06

Shown on the compressor (1) with 352 cm3 displacement

1	Compressor
2	Cylinder head
9	Seal (suction valve disk)
10	Bolts
11	Bolts
A	Sealing web

G13.30-3175-06

Shown on the compressor (1) with 393 cm3 displacement

1	Compressor
2	Cylinder head
9	Seal (suction valve disk)
11	Bolts
12	Guide pins
13	Screw

G13.30-3136-06

 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on coolant		AH20.00-N-2080-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
 	Remove/install
1	Charge the compressed air system up to shutoff pressure.
2	Switch off ignition.
3.1	Tilt cab to repair position.	Model 405, 437.42/43
			AR60.80-G-0005B
		 Installation: Only tilt back cab after the leak test.
3.2	Open hood.	Model 437.465
		 See information from body manufacturer.
		 Installation: Only close the engine hood after the leak test.
4	Fully remove air filter housing.	Only on model 405.05
5	Remove engine cover.	Only on model 405.05	AR01.10-G-2405E
6	Remove side engine cover on left.
7	Check return flow valve in the pressure regulator for the air drier for leaktightness.	Model 405, 437	AR42.60-G-0025B
8	Remove the elbow fitting (4.1).	 Installation: When tightening the elbow fitting (4.1), hold the threaded fitting (4.2) against it.
9	Remove retaining clamp for control line (7) from compressed air line (5).	Only in engine 900.915/916, 902.923/924 in model 405 with compressor 352 cm3 displacement, engine 900.920/921, 924.923/931 in model 437.42/43 with compressor 352 cm3 displacement
		 Installation: The cylinder heads (2) of the compressors (1) with 238 cm3 and 352 cm3 displacement have been standardized and optimized starting with vehicle identification end number 227667. For conversion to the harmonized and optimized cylinder head (2) the retaining clamp is no longer required.
10	Remove control line (7) up to the connecting point.	Only in engine 900.915/916, 902.923/924 in model 405 with compressor 352 cm3 displacement, engine 900.920/921, 924.923/931 in model 437.42/43 with compressor 352 cm3 displacement
		 Installation: For conversion to the harmonized and optimized cylinder head (2) is the control line (7) is no longer required. Close off the connection for the connecting point with a ball (8.1) and union nut (8.2). Bind the line remaining in the vehicle with cable ties on the frame.
11	Slowly open cap on coolant expansion reservoir and then close it again.	 In order to reduce the overpressure in the cooling system.
12	Remove coolant line (3) from cylinder head (2) and collect escaping coolant with suitable container.	 Do not open cap on coolant expansion reservoir.
		 Installation: Install new sealing rings.
		 Banjo bolt, coolant line to compressor	*BA13.30-N-1004-01I
13	Close off coolant line (3), as shown, with screw/bolt, sealing rings and nut.
14	Remove coolant line (6) from the compressor's (1) cylinder head (2) and collect escaping coolant with suitable container.	 Installation: The cylinder heads (2) of the compressors (1) with 238 cm3 and 352 cm3 displacement have been standardized and optimized starting with vehicle identification end number 227667. For conversion to the harmonized and optimized cylinder head (2) for Euro IV/V standard engines, the longer coolant line (6) for Euro III standard engines must be installed.
		 Installation: Install new sealing rings.
		 Banjo bolt, coolant line to cylinder head	*BA01.30-N-1005-01M
		 Banjo bolt, coolant line to compressor	*BA13.30-N-1004-01I
15	close off coolant line (6) with a screw/bolt, sealing rings and nuts.
16	Remove retaining clamp of compressed-air line (5).
17	Remove compressed air line (5).
18	Remove air intake line from the compressor (1).
19	Pull out the TDC - sensor for cylinder 1 (B16) from timing case and seal openings with suitable stop plugs.	 Do not disconnect electrical connection.
		 Installation: Press in the TDC sensor cylinder 1 (B16) up to the end stop.
		 Record plug	*129589009100
20.1	Remove screws (10, 11) and remove cylinder head (2).	Compressor (1) with 238 cm3 and 352 cm3 displacement or with standardized and optimized cylinder head (2).
			AR13.30-G-6010-01B
		 Installation: Tighten the screws/bolts (10, 11) in line with the prescribed tightening procedure. Leaks on cylinder head (2) can occur otherwise.
		 Installation: Install new seal (9). The sealing web (A) must point towards the cylinder head (2). Replace all screw/bolts (10). Install the cylinder head (2) in a cold condition.
		 Screw, cylinder head to crankcase (optimized cylinder head, compressor with 238 cm3 or 352 cm3 displacement, attached with four hexagon head bolts)	*BA13.30-N-1002-01I
		 Screw, upper part of cylinder head to lower part of cylinder head (compressor with 238 cm3 or 352 cm3 displacement, attached with one or three round Allen head bolts)	*BA13.30-N-1009-01I
		 Screw, upper part of cylinder head to lower part of cylinder head (optimized cylinder head, attached with two round Allen head bolts)	*BA13.30-N-1010-01I
20.2	Remove screws/bolts (11, 13) and cylinder head (2).	Compressor (1) with 393 cm3 displacement.
			AR13.30-G-6010-01B
		 Installation: Tighten the screws/bolts (11, 13) in line with the prescribed tightening procedure. Leaks on cylinder head (2) can occur otherwise.
		 Installation: Remove both guide pins (12) from the cylinder head (2) and replace the seal (9). Replace all new screw/bolts (11, 13). Install the cylinder head (2) in a cold condition.
		 Screw, cylinder head to crankcase (compressor with 393 cm3 displacement, attached with eight round Allen head bolts)	*BA13.30-N-1011-01I
		 Screw, upper part of cylinder head to lower part of cylinder head (compressor with 393 cm3 displacement, attached with one round Allen head bolt)	*BA13.30-N-1012-01I
21	Remove the threaded fitting (4.2).	Only when replacing the cylinder head (2).
		 Installation: Replace sealing ring.
		 Threaded fitting, compressed-air line to compressor	*BA13.30-N-1007-01I
	Check
22	Check piston and cylinder barrel on the compressor (1) for damage and wear.	If problems exist,
		
		Replace compressor (1).
		Model 437.465 to 31.03.17 with engine 924.916, 405, 437.42/43	AR13.30-G-0001BC
		Model 437.465 as of 4/1/17 with engine 924.916	AR13.30-G-0001CM
23	Check elbow fitting (4.1), threaded fitting (4.2), air line (5), cylinder head upper part and cylinder head lower part for carbonization.	If problems exist,
		
		Replace carbonized components.
24	Check air intake duct on compressor (1) for damage.	If problems exist,
		
		replace the air intake line.
25	Check the resonator for compressor (1) for damage.	Only for engine 902, 906 in model 405
		If problems exist,
		
		replace the resonator.
26	Install in the reverse order
27	Retrofit pressure limiting valve in compressed air system.	Only for model 405.050/101/103/121/123/201/221 with engine 900.915/916, 902.923/924/935, 906.935 Only in event of modification to the harmonized and optimized cylinder head (2) without "power reduction".
	Service Information: Install additional pressure limiting valve in high-pressure control circuit of compressed air system	MODEL 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666	SI42.60-G-0011A
		Model 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666 with code A54 (Preparation for auxiliary rear axle steering)	AN42.60-G-0014B
		Model 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666 with code A54 (Preparation for auxiliary rear axle steering)	AN42.60-G-0014BB
	Check
28	Correct coolant level.
		Model 405	AP20.00-G-2010B
		Model 437.4	AP20.00-G-2010C
29	Purge engine cooling system.	Only on model 405	AR20.00-G-1040B
30	Check engine cooling system for leak tightness.	 Visual inspection.
31	Check compressor (1), cylinder head (2) and air line (5) for leaktightness.	 Visual inspection.
32	Check connecting point of the control line (7) for leaktightness.	If installed.
		 Visual inspection.

 Cylinder head

Number	Designation		Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96
BA01.30-N-1005-01M	Banjo bolt, coolant line to cylinder head	Nm	40