Remove/install left cylinder head

AR01.30-D-5770SF

Remove/install left cylinder head

18.02.2020

Engine

642.896/898/992/993 in model 906

Shown on engine 642.992

2

Oil filter housing

6

Screw

9

Bracket

3

Screw

7

Screw

10

Left cylinder head

4

Fuel line

8

Heat shield

16

High pressure pump

5

Exhaust manifold

10

Left cylinder head

12

Cylinder head seal

13

Cylinder head bolt

14

Cylinder head bolt

15

Crankcase

 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

 Danger

Risk of explosion caused by 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 explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove charge air distributor

Engine 642.896/898 in model 906

AR09.41-D-1310SG

Engine 642.992 in model 906

AR09.41-D-1310SF

Engine 642.993 in model 906

AR09.41-D-1310S

2

Remove oil filter housing (2)

AR18.20-S-3471SE

3

Remove high-pressure pump (16)

AR07.02-D-1020SF

4

Remove camshafts in left cylinder head (10)

AR05.20-D-6992SF

5

Remove hydraulic valve play compensation elements on left cylinder head (10)

AR05.00-S-2011SE

6

Remove screw/bolts (6, 7) and remove heat shield (8)

 Installation: Pay attention to different screw/bolt lengths (6, 7).

7

Remove screw/bolt (3) and place fuel lines (4) to one side

8

Remove bracket (9)

9

Remove guide rail pins at left cylinder head (10)

AR01.30-S-5800-04SE

 Installation: Screw suitable screw/bolt into slide rail bolt, drive slide rail bolt into left cylinder head (10) and remove screw/bolt again.

 Puller

*605589003300

10

Loosen and remove cylinder head bolts (13, 14) in stages for a cooled down engine and in reverse order of the tightening procedure

AR01.30-S-5800-01SE

 Installation:
Observe tightening procedure and tightening specifications for cylinder head bolts (13, 14).
Warping of the left cylinder head (10) can occur otherwise.

 Installation: Lightly lubricate thread and bolt head contact surface for cylinder head bolts (13, 14).

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01Q

11

Remove left cylinder head (10) and cylinder head gasket (12) from crankcase (15)

 Installation: Install new cylinder head gasket (12).

12

Remove exhaust manifold (5) from left cylinder head (10)

Only when replacing left cylinder head (10).

AR14.10-D-3930SF

13

Cover cylinder bores and contact surface on crankcase (15)



Clean

14

Clean threaded holes of cylinder head bolts (13, 14) in crankcase (15)

 Blow dirt or fluid out of the threaded holes.

15

Clean sealing surfaces at left cylinder head (10) and at crankcase (15)

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A



Check

16

Check stud bolts on exhaust manifold (5) on left cylinder head (10) for damage

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-01O

Depending on findings



Replace damaged stud bolts

17

Check cylinder head bolts (13)

AR01.30-S-5800-03SE

Cylinder head bolt

*BE01.30-N-1001-04A

Depending on findings



Replace cylinder head bolts (13)

18

Check left cylinder head (10) and crankcase (15) for damage

 Reworking of the sealing surfaces on the left cylinder head (10) or on the cylinder crankcase (15) is not permissible.

Depending on findings



Replace left cylinder head (10) or crankcase (15)

19

Install in the reverse order



Check

 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

20

Check for leak tightness with engine running

 Visual inspection only.

Check values for cylinder head/cylinder head bolts

Number

Designation

Engine 642 in model 906

BE01.30-N-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

205

Max. length (L)

mm

207

For picture, see

AR01.30-S-5800-03SE

 Cylinder head

Number

Designation

Engine 642 in model 906

BA01.30-N-1001-01Q

Screw/bolt, cylinder head to crankcase

M8

Nm

20

M12

Stage 1

Nm

10

Stage 2

Nm

60

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

 Exhaust manifold

Number

Designation

Engine 642 in model 906

BA14.10-N-1002-01O

Stud bolt, exhaust manifold to cylinder head

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09