Remove/install cylinder head

AR01.30-D-5800R

Remove/install cylinder head

18.12.09

 

Remove/install

1

Disconnect ground cable from battery

2

Take off fixture of injection lines (13)

3

Detach leak oil lines (11)

4

Remove injection line (12)



*BA07.13-N-1001-01A

5

Remove intake manifold

AR09.20-D-1310A

6

Remove camshaft

AR05.20-D-6292A

7

Remove oil-water heat exchanger

AR18.30-D-6840A

8

Slacken poly-V-belt, remove

 Installation: Hexagon bolt (22) for attaching tensioning lever must be inserted into the cylinder head before installing the intake manifold.

AP13.22-D-1381-01B

9

Unbolt dipstick guide tube at cylinder head (18)



*BA01.45-N-1012-01H

10

Unscrew bolt (17) of shock absorber of poly-V-belt tensioning device to cylinder head



*BA13.25-N-1003-01B

11

Remove fuel filter (4)

 Place fuel filter to the side with lines connected and attach to the vehicle.

12

Detach coolant hoses (9, 10) at cylinder head

13

Remove coolant pipe at cylinder head

14

Unplug electrical connections at the cylinder head

AR01.30-D-5800-08A

15

Pull out guide rail pins in cylinder head

AR01.30-D-5800-04B



*605589003300

 Installation: Coat guide rail pins with sealant.

*BR00.45-Z-1012-01A

16

Unbolt shield (23)

17

Detach intake air hose (27) and charge air hose (28) at turbocharger

18

Unbolt exhaust pipe (31) from turbocharger (20)



 Installation: Install new nuts.

*BA49.10-N-1002-01B

19

Unbolt bracket of exhaust pipe (21)

20

Unbolt and remove pressurized oil line (22) from turbocharger (20) and from crankcase

 Installation: Install new sealing rings (22b).

21

Unbolt connector for oil return flow line (24) at crankcase

 Installation: Install new O-rings (25) and new gasket (24a).

22

Unbolt support (30) of turbocharger to carrier of alternator

23

Slacken cylinder head bolts (2, 3) in stages, unscrew

 Pay attention to slackening pattern in order to avoid damage caused by stresses.

AR01.30-D-5800-09A



*601589001000

 Installation: Tighten bolts according to tightening procedure. It is not necessary to retighten the cylinder head bolts (3).

AR01.30-D-5800-01A



*116589030700



*BA01.30-N-1002-01B



*BA01.30-N-1003-01B

24

Remove cylinder head (1)

 Installation: Inspect cylinder head gasket (16), replace.

Pay attention to guide rails when fitting on cylinder head.

Pay attention to dowel sleeves (15) for locating the cylinder head.

25

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

Visual inspection!

26

Inspect cylinder walls for scores and signs of grooves

Blow out threaded holes

 Free of oil and water

27

Check cylinder head bolts (3)

AR01.30-D-5800-03A



*BE01.30-N-1001-01A

28

Install in the reverse order

29

Check engine for leaks

30

Inspecting cooling system for leaks

 Do not pressure-test cooling system until engine has reached operating temperature

as the cylinder head gasket is not watertight until the engine has reached operating temperature and the gasket has swollen.

AR20.00-D-1010A

Number

Designation

Engines
602.980/984/985

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

AR01.30-P-5800-03HA

Number

Designation

Engine 602.980

BA07.13-N-1001-01A

Injection lines to injection nozzle/injection pump

Nm

18

Number

Designation

Engine 602.980

BA13.25-N-1003-01B

Shock absorber on cylinder head

Nm

23

Number

Designation

Engine
602.980

BA01.45-N-1012-01H

Bolt, oil dipstick guide tube to cylinder head

Nm

9

Number

Designation

Engine
602.980

BA49.10-N-1002-01B

Flange connection for front exhaust system - turbocharger

Nm

23

Number

Designation

Engine 602.980

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

23

Number

Designation

Order number

BR00.45-Z-1012-01A

Omnifit FD 3041 sealant

A 002 989 47 20 10