Remove/install cylinder head

AR01.30-D-5800AD

Remove/install cylinder head

01.07.2019

Engine

900.917/918/919 in model 668, 670

Modification notes

17.02.2012

Basic data, newly added

Operation step 8

BA14.40-N-1010-02E

01.01.1970

BA14.40-N-1012-02E

2

Charge air pipe

6

Banjo bolt

10

Bracket

3

Turbocharger

7

shielding plate upper part

13

Oil pressure line

4

Clip

8

Coolant line

Y107

Feed line SCR tank heater solenoid valve

5

Exhaust pipe

9

Electrical connector

Y109

SCR AdBlue metering valve

1

Cylinder head

3

Turbocharger

14

Exhaust manifold

15

Screw

L

Shank length

1

Cylinder head

16

Coolant line

17

Injection line

18

Fuel return line

19

Oil dipstick guide tube bracket

20

Push rods

21

Constant throttle air line

1

Cylinder head

24

Electrical connector

27

Bolts

22

Cylinder head bolts

25

Connection fitting

28

Coolant hoses

23

Coolant pump

26

Connection piece

 

Remove/install

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

 Danger

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

No fires, 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

1

Disconnect ground line from battery

Topical note

Notes on battery

AH54.10-P-0001-01A

2

Remove passenger seat

 Front bolt, front passenger seat to body

*BA91.10-N-1001-01D

 Rear bolt, front passenger seat to body

*BA91.10-N-1002-01D

3

Remove maintenance hood

 Installation: Install maintenance hood only after the leak test.

4

Drain off coolant

AR20.00-D-1142AD

5

Release oil pressure line (13) from the exhaust gas turbocharger (3) and remove from oil filter housing

AR09.40-D-6024AD

6

Remove charge air pipe (2) from the exhaust gas turbocharger (3) to the charge air cooler

AR09.41-D-1311AD

7

Disconnect electrical connector (9) from the charge air and intake pressure sensor

 Warning

Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue

Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

8

Remove bracket (10) with SCR AdBlue metering valve (Y109) and remove SCR feed line tank heater solenoid valve (Y107)

AR14.40-D-2023-01AD

Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A

 Banjo bolt, compressed air line to metering device

*BA14.40-N-1010-02E

 Union nut, injection line to metering device

*BA14.40-N-1012-02E

9

Remove shielding plate upper part (7)

AR09.40-D-6020-01AD

 Bolt, shield to turbocharger

*BA09.40-N-1004-01B

 Bolt, shield to charge air manifold

*BA09.41-N-1009-01B

10

Release clamp (4) from exhaust pipe (5)

11

Remove exhaust manifold (14) from cylinder head (1)

 Installation: Measure shank length (L) of the screws (15).
If the maximum shank length (L) was exceeded, install new screws (15).

Exhaust manifold bolts

*BE14.10-N-1001-01A

 Bolt, exhaust manifold to cylinder head

*BA14.10-N-1001-01B

12

Extend exhaust manifold (14) together with the exhaust gas turbocharger (3) out of the exhaust pipe (5) and place to one side

13

Remove coolant line (8)

14

Remove rocker arm assembly

AR05.00-D-5521AD

15

Remove pushrods (20)

 Installation: Lubricate pans of the pushrods (20) with engine oil. Ensure pushrods (20) are seated correctly in the tappets.

16

Remove injection lines (17)

AR07.15-D-9235AD

17

Remove constant throttle air line (21) from the cylinder head (1)

For code MB1 (engine brake with constant throttle)

18

Remove fuel return line (18) from cylinder head (1)

 Banjo bolt, fuel line to cylinder head

*BA07.15-N-1006-01A

19

Release coolant line (16) from cylinder head (1)

20

Remove oil dipstick guide tube bracket (19) from the cylinder head (1)

 Oil dipstick guide tube bracket to cylinder head

*BA01.30-N-1003-01C

21

Remove screws (27) and pull connection piece (26) upward (arrow) out of the coolant pump (23)

 Do not disconnect coolant hoses (28) and electrical connector (24).

 Installation: Check connection fitting (25); replace if necessary.

 Bolt, connection piece for coolant pump to cylinder head

*BA20.10-N-1003-01C

22

Remove cylinder head bolts (22) in reverse order of the tightening specification

AR01.30-D-5800-07AD

 Installation: Lubricate cylinder head bolts (22) with engine oil.
Observe tightening specifications for cylinder head bolts (22).

 Cylinder head bolts on crankcase

*BA01.30-N-1002-01C

 Socket wrench bit

*422589020900

23

Remove cylinder head (1) from cylinder crankcase

AR01.30-D-5800-11AD


Do not set down cylinder head (1) on the sealing surface.
Otherwise, the installed nozzle holder assemblies will be damaged.

24

Clean cylinder head (1)

Topical note

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

25

Clean thread, oil, and coolant bores in the cylinder crankcase and cylinder crankcase contact surface

Topical note

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

 Cover oil and coolant bores in the cylinder crankcase.



Check

26

Check cylinder head (1) for cracks and damage

 In the event of cracks and damage, replace cylinder head (1) and change detachable parts.

27

Check flatness of cylinder head (1)

AR01.30-D-5800-12AD

 Use feeler gauge and straightedge.

Permissible variation in flatness of lower separating surface in a longitudinal direction

*BE01.30-N-1002-02B

If there are complaints:



Face-grind the cylinder head separating surface

AR01.30-D-7162AD

28

Inspect flatness of crankcase separating surface

AR01.40-D-9133-01AD

 Use feeler gauge and straightedge.

Crankcase flatness of separating surface

*BE01.40-N-1013-02B

If there are complaints:



Check cylinder crankcase sealing surface and repair

AR01.40-D-9129AD

29

Check shank length of the cylinder head bolts (22)

AR01.30-D-5800-03AD

Cylinder head bolts

*BE01.30-N-1001-01B

30

Install in the reverse order

31

Check engine oil level with oil dipstick; correct if necessary



BB00.40-P-0228-05A

 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

32

Start engine and observe oil pressure indicator with the engine running at idle speed

 Do not rev up engine before oil pressure is indicated. After approx. 10 s, the oil pressure display must show the oil pressure.
Start engine with starter for max. 90 s. Wait at least for about 2 minutes before repeating attempt at starting. The fuel system is bled automatically.

Engine oil pressure at

*BE18.00-N-1001-01C

33

Turn off engine and check area of installed cylinder head (1) for leaktightness

34

Set the time and radio and synchronize tachograph

Check values for cylinder head bolts

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BE01.30-N-1001-01B

Cylinder head bolts

Thread

M

162

Length of shank when new

mm

149,0

Permissible shank length

mm

151,0

Check values for cylinder head

Number

Designation

ENGINE 900.9, 904.9

BE01.30-N-1002-02B

Permissible variation in flatness of lower separating surface in a longitudinal direction

over the entire length

mm

0,05

Over a length of 150 mm

mm

0,02

Check values of crankcase

Number

Designation

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0,030

Over a length of 150 mm in longitudinal or Transverse direction

mm

0,015

Check values for exhaust manifold

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BE14.10-N-1001-01A

Exhaust manifold bolts

Thread diameter

M

10

Length of shank when new

mm

47,0

Permissible shank length

mm

47,5

Check values of engine oil pressure

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

idle speed

bar

0,5

maximum speed

bar

2,5

 Cylinder head

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA01.30-N-1002-01C

Cylinder head bolts on crankcase

Stage 1

Nm

20

Stage 2

Nm

70

Stage 3

Nm

170

Stage 4

Nm

280

Stage 5

°

90

Stage 6

°

90

 Cylinder head

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA01.30-N-1003-01C

Oil dipstick guide tube bracket to cylinder head

Nm

50

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

ENGINE 900.9, ENGINE 902.9 except CODE MS8

BA07.15-N-1006-01A

Banjo bolt, fuel line to cylinder head

Nm

50

 Turbocharger

Number

Designation

ENGINE 900.9, 904.9

BA09.40-N-1004-01B

Bolt, shield to turbocharger

Nm

25

 Charge air pipe/charge air cooling

Number

Designation

Engine 900.9 in model 668, 670

BA09.41-N-1009-01B

Bolt, shield to charge air manifold

Nm

25

 Exhaust manifold

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA14.10-N-1001-01B

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

Stage 2

Nm

55

Stage 3

°

90

 Exhaust aftertreatment, Blue Tec

Number

Designation

Engine 900.9 in model 668, 670

BA14.40-N-1010-02E

Banjo bolt, compressed air line to metering device

Nm

15

 Exhaust aftertreatment, Blue Tec

Number

Designation

Engine 900.9 in model 668, 670

BA14.40-N-1012-02E

Union nut, injection line to metering device

Nm

17

 Coolant pump, coolant thermostat

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA20.10-N-1003-01C

Bolt, connection piece for coolant pump to cylinder head

Nm

50

 Front seats

Number

Designation

Model 667, 668, 670

BA91.10-N-1001-01D

Front bolt, front passenger seat to body

Nm

20

 Front seats

Number

Designation

Model 667, 668, 670

BA91.10-N-1002-01D

Rear bolt, front passenger seat to body

Nm

28