Remove/install right cylinder head

AR01.30-D-5780SF

Remove/install right cylinder head

18.02.2020

Engine

642.896/898/992/993 in model 906

Shown on engine 642.992

1

Right cylinder head

5

Exhaust manifold

8

Engine wiring harness

3

Bracket

6

Screw

9

Mixing chamber

4

Screw

7

Bracket

N14/3

Glow output stage

Shown on engine 642.896

5

Exhaust manifold

8

Engine wiring harness

16

Bracket (for engine 642.896/898/993.)

17

Bracket (for engine 642.896/898/993.)

18

Grounding line (for engine 642.896/898/993)

1

Right cylinder head

11

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

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

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 mixing chamber (9)

Engine 642.896/898 in model 906

AR09.20-D-1320SG

Engine 642.992 in model 906

AR09.20-D-1320SF

Engine 642.993 in model 906

AR09.20-D-1320S

2

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

3

Remove exhaust gas recirculation

Engine 642.896/898/993 in model 906

AR14.20-D-1050SG

4

Remove engine wiring harness (8) from bracket (16)

Engine 642.896 in model 906

5

Remove bracket (16) on exhaust gas recirculation from right cylinder head (1)

Engine 642.896/898/993 in model 906

6

Remove ground line (18) from right cylinder head (1)

Engine 642.896/898/993 in model 906

7

Remove bracket (17) on exhaust pipe from right cylinder head (1)

Engine 642.896/898/993 in model 906

 Bolt, bracket for front exhaust system to cylinder head

*BA49.10-N-1004-01M

8

Remove exhaust manifold (5) from right cylinder head (1) and lay down to side

Engine 642.896/898/993 in model 906

 Installation: Replace seal.

 Nut, exhaust manifold to cylinder head

*BA14.10-N-1001-01O

9

Remove camshafts in right cylinder head (1)

AR05.20-D-6992SF

10

Remove hydraulic valve play compensation elements on right cylinder head (1)

AR05.00-S-2011SE

11

Remove screw/bolt (6) from bracket (7)

Engine 642.992 in model 906

12

Disconnect electrical connection to glow output stage (N143) and remove glow output stage (N143) with holder (7)

Engine 642.992 in model 906

13

Disconnect electrical connections to glow plugs (arrows) and expose engine wiring harness (8) on right cylinder head (1)

 Pliers

*611589003700

14

Remove guide rail pins at right cylinder head (1)

AR01.30-S-5800-04SE

 Installation: Screw suitable screw/bolt into slide rail bolt, drive slide rail bolt into right cylinder head (1) and remove screw/bolt again.

 Puller

*605589003300

15

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 right cylinder head (1) 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

16

Remove right cylinder head (1) and cylinder head gasket (11) from crankcase (15)

 Installation: Replace cylinder head gasket (11).

17

Remove exhaust manifold (5) from right cylinder head (1)

Only when replacing the right cylinder head (1).

Engine 642.992 in model 906

AR14.10-D-4005SF

18

Remove screw/bolts (4) and holder (3) for exhaust system on right cylinder head (1)

Only when replacing the right cylinder head (1).

 Bolt, bracket for front exhaust system to cylinder head

*BA49.10-N-1004-01M

19

Cover cylinder bores and contact surface on crankcase (15)



Clean

20

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

 Blow dirt or fluid out of the threaded holes.

21

Clean sealing surfaces at right cylinder head (1) 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

22

Check stud bolts on exhaust manifold (5) on right cylinder head (1) for damage

Engine 642.896/898/993 in model 906

Depending on findings



Replace stud bolts

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-01O

23

Check exhaust manifold (5) for crack formation and damage

If the exhaust manifold (5) is torn or damaged.



Remove exhaust manifold (5)

AR14.10-D-4005SF

24

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)

25

Check right cylinder head (1) and crankcase (15) for damage

 Reworking of the sealing surfaces on the right cylinder head (1) or on the cylinder crankcase (15) is not permissible.

Depending on findings



Replace right cylinder head (1) or crankcase (15)

26

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

27

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-1001-01O

Nut, exhaust manifold to cylinder head

Stage 1

Nm

25

Stage 2

Nm

-

 Exhaust manifold

Number

Designation

Engine 642 in model 906

BA14.10-N-1002-01O

Stud bolt, exhaust manifold to cylinder head

Nm

20

 Exhaust system

Number

Designation

Engine 642.896/898 in model 906

Engine 642.992/993

BA49.10-N-1004-01M

Bolt, bracket for front exhaust system to cylinder head

Nm

8

8

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