Remove/install cylinder head

AR01.30-P-5800MFF

Remove/install cylinder head

18.02.2020

Engine

654 in model 118, 177, 247

Modification notes

23.08.2019

Note added.

Operation step 16

1

Cylinder head

7

Screw

2

Bolts

8

Lifting eye at the front

3

Fuel line

14

Slide rail

4

Screw

15

Timing chain

5

Bracket

16

Spur gear

6

Bolts

17

Screw

9

Bolts

10

Bracket

8

Lifting eye at the front

11

Bolts

12

Bolts

13

Engine support

19

Exhaust manifold

20

Coolant line

21

Lifting eye at the rear

 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 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on coolant level

AH20.00-P-1142-01CW



Remove

1

Remove exhaust gas aftertreatment unit.

AR49.20-P-1500MFF

2

Remove exhaust gas turbocharger.

AR09.40-P-6020MFF

3

Remove low-pressure exhaust gas recirculation cooler.

AR14.20-P-7681MFF

4

Remove high-pressure exhaust gas recirculation cooler.

AR14.20-P-7682MFF

5

Remove charge-air distributor.

AR09.41-P-8683MFF

6

Remove hydraulic valve play compensation elements.

AR05.00-P-2011MFF

7

Remove bolts (2) and remove fuel line (3) from cylinder head (1).

8

Remove screw (4) and remove bracket (5) from cylinder head (1).

9

Remove bolts (6) of coupling flange at front lifting lug (8).

10

Remove screw (7) of fuel line at front lifting lug (8).

11

Remove slide rail (14).

AR05.10-P-8421MFF

12

Remove screw (17).

13

Detach spur gear (16) and remove from timing chain (15).

 Secure timing chain(15) against falling down.

14

Remove bolts (9) from bracket (10) and remove bracket (10).

15

Remove bolts (11, 12) in reverse order to tightening procedure.

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01OLC


Remove bolts (11, 12) when engine has cooled down.
Stresses can occur in the cylinder head (1) otherwise.

16

Remove cylinder head (1) with exhaust manifold (19).

General information on checking valves, valve seats and valve guides

AH05.30-P-1000-02SZ

 Aid of helper required.



Clean

17

Clean sealing surfaces on cylinder head (1) and on crankcase.


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

18

Cover threaded holes of bolts (11, 12) in crankcase with rags and clean with compressed air.



Check

19

Check cylinder head (1) and crankcase for damage and unevennesses.

 Do not rework sealing surfaces at cylinder head (1) and crankcase.

 Straightedge

*452589019924

If problems exist,



Replace cylinder head (1), timing case cover and crankcase.

Crankcase
Engine 654 in model 118, 177, 247 with transmission 711.63

AR01.10-P-2401MFS

Crankcase
Engine 654 in model 118, 177, 247 with transmission 724.1

AR01.10-P-2401MFF

Timing case cover

AR01.40-P-8000MFF

20

Check length of bolts (11).

AR01.30-P-5800-03T

Cylinder head bolt

*BE01.30-P-1001-04E

If problems exist,



Replace bolts (11).

Modify

21

Modify coolant line (20).

When replacing the cylinder head (1).

 Install new sealing rings.

 M61

*BA00.10-P-1002-04A

 Assembly tool

*000589936300

22

Modify exhaust manifold (19).

When replacing the cylinder head (1).

AR14.10-P-3006MFF

23

Modify front lifting lug (8).

When replacing the cylinder head (1).

 Lifting eye at cylinder head (cross-installed)

*BA01.30-P-1008-01V

24

Modify engine carrier (13).

When replacing the cylinder head (1).

 Screw, engine support to cylinder head (transverse installation)

*BA22.10-P-1009-02A

25

Modify rear lifting lug (21).

When replacing the cylinder head (1).

 Lifting eye at cylinder head (cross-installed)

*BA01.30-P-1008-01V

26

Modify glow plugs.

When replacing the cylinder head (1).

AR15.20-P-4111MFF

27

Modify valves.

When replacing the cylinder head (1).

AR05.30-P-3511MFF



Install

28

Mount cylinder head gasket on crankcase.

 Use a new cylinder head gasket.
Pay attention to installation position.

29

Position cylinder head (1) on crankcase.

 Aid of helper required.

30

Slightly wet thread and bolt head contact surface of bolts (11) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

31

Slightly screw in bolts (11, 12) by hand and tighten in sequence of tightening procedure.

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01OLC

 Bolt, cylinder head to timing case cover

*BA01.30-P-1001-01V

 Screw/bolt, cylinder head to crankcase

*BA01.30-P-1002-01V

32

Install bracket (10) and tighten bolts (9).

 Screw, holder to crankcase/cylinder head

*BA49.10-P-1004-02V

33

Position timing chain(15) on intermediate gear(16) and install intermediate gear (16).

34

Tighten screw (17).

 Bolt, journal/intermediate gear to cylinder head

*BA05.10-P-1001-02B

35

Install slide rail (14).

AR05.10-P-8421MFF

36

Tighten screw (7) of fuel line at front lifting lug (8).

 M61

*BA00.10-P-1002-04A

37

Tighten bolts (6) of coupling flange at front lifting lug (8).

 Screw/bolt, charge air line to support

*BA09.41-P-1006-01Y

38

Install bracket (5) at cylinder head (1) and tighten screw (4).

 M61

*BA00.10-P-1002-04A

39

Position fuel line (3) and tighten bolts (2).

 M61

*BA00.10-P-1002-04A

40

Install hydraulic valve play compensation elements.

AR05.00-P-2011MFF

41

Install charge-air distributor.

AR09.41-P-8683MFF

42

Install high-pressure exhaust gas recirculation cooler.

AR14.20-P-7682MFF

43

Install low-pressure exhaust gas recirculation cooler.

AR14.20-P-7681MFF

44

Install exhaust gas turbocharger.

AR09.40-P-6020MFF

45

Install exhaust gas aftertreatment unit.

AR49.20-P-1500MFF

 Only install lower engine compartment lining and upper engine cover after leak test.

46

Perform engine oil and oil filter change.



AP18.00-P-0101FA

 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

47

Carry out engine test run and check engine for proper leaktightness and leaktightness.

48

Install lower engine compartment lining.

AR61.20-P-1105MFE

49

Install upper engine cover.

AR01.10-P-2405MFF

Cylinder head/cylinder head bolts

Number

Designation

Engine 654

BE01.30-P-1001-04E

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

215 (0,5)

Max. length (L)

mm

217

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Tightening torques, cylinder head

Number

Designation

Engine 654

BA01.30-P-1001-01V

Bolt, cylinder head to timing case cover

M8

Nm

20

 Tightening torques, cylinder head

Number

Designation

Engine 654

BA01.30-P-1002-01V

Screw/bolt, cylinder head to crankcase

M12

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

Stage 6

°

90

 Tightening torques, cylinder head

Number

Designation

Engine 654

BA01.30-P-1008-01V

Lifting eye at cylinder head (cross-installed)

Nm

29

 Gearwheel drive

Number

Designation

Engine 654

BA05.10-P-1001-02B

Bolt, journal/intermediate gear to cylinder head

Nm

57

 Charge air pipe/charge air cooling

Number

Designation

Engine 654

BA09.41-P-1006-01Y

Screw/bolt, charge air line to support

Nm

8

 Engine support (engine side)

Number

Designation

Engine 654

BA22.10-P-1009-02A

Screw, engine support to cylinder head (transverse installation)

Stage 1

Nm

20

Stage 2

°

90

 Exhaust system

Number

Designation

Engine 654 in model 118

Engine 654 in model 177

BA49.10-P-1004-02V

Screw, holder to crankcase/cylinder head

M8

Nm

20

20

 Exhaust system

Number

Designation

Engine 654 in model 247

BA49.10-P-1004-02V

Screw, holder to crankcase/cylinder head

M8

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09