Remove/install cylinder head

AR01.30-T-5800B

Remove/install cylinder head

10.5.00



Removal

 Danger!

Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. 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 bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

 Danger!

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

Wear protective gloves, protective clothing and (where necessary) safety glasses.

AS00.00-Z-0002-01A

1

Open tailgate or remove engine compartment flap

 Depending on cylinder to be removed.

Remove/install engine compartment flap

AR88.40-T-1100B

2

Drain coolant



Notes on coolant

All engines

AH20.00-N-2080-01A



Drain coolant, refill

AP20.00-T-2080-01B

3

Remove charge air passages

 After this, detach leak oil lines at the injectors.

AR09.41-T-8620B

4

Take off exhaust manifold

 Only slacken all the bolts at the exhaust manifold. Unscrew the bolts at the cylinder head to be removed.

5

Remove cylinder head cover (1)

AR01.20-T-5014B

6

Remove rocker arm bearing bracket (2)

AR05.20-T-2340B

7

Take cylinder head (3) off the crankcase

AR01.30-T-5800-11B



*403589020300



*422589000900



Check

8

Check cylinder head contact surface and machine if necessary

AR01.30-T-7162B

9

Inspect contact surface of crankcase



Install

10

Mount cylinder head (3) onto the crankcase

AR01.30-T-5800-11B



*403589020300

11

Tighten cylinder head (3) as specified in tightening diagram

AR01.30-T-5800-07B



*000589620901



*403589020300



*422589000900

*BE01.30-N-1001-01E



*BA01.30-N-1001-01H

12

Install rocker arm bearing bracket (2)

AR05.20-T-2340B

13

Install cylinder head cover (1)

AR01.20-T-5014B

14

Fit on exhaust manifold

 Replace exhaust manifold gasket.



*BA14.10-N-1002-01E



*BA14.10-N-1004-01E



*BA14.10-N-1006-01E

15

Install charge air passages

 After this, fit leak oil lines onto the injectors.

AR09.41-T-8620B

16

Pour in coolant



*BF20.00-N-1001-01D



Notes on coolant

All engines

AH20.00-N-2080-01A



Drain coolant, refill

AP20.00-T-2080-01B

17

Close tailgate or install engine compartment flap

 Depending on cylinder to be removed.

Remove/install engine compartment flap

AR88.40-T-1100B

Number

Designation

Engines
402.970,
441.980,
446.938

Engine 447

Engine 489

BE01.30-N-1001-01E

Cylinder head bolt
M15X2

Shank length

mm

 111,0

109,0

109,0

Shank length

mm

 146,0

144,0

144,0

Shank length

mm

 170,0

168,0

168,0

Number

Designation

Engine
402.970

Engine
441.980

Engine
446.938

BA01.30-N-1001-01H

Cylinder head bolt to crankcase

1st stage

NM

10

10

10

2nd stage

NM

50

50

50

Step 3

NM

100

100

100

4th stage

NM

145

145

145

5th stage

NM

-

185

185

6th stage

°

95

95

95

Fig. see

-

-

-

Number

Designation

Engine 441.980

BA14.10-N-1002-01E

Bolt, exhaust pipe to exhaust manifold

NM

50

Number

Designation

Engine 402.970

Engine 441.980

Engine 446.938

BA14.10-N-1004-01E

Bolt, exhaust manifold to cylinder head

NM

50

50

50

BA14.10-N-1006-01E

Nut, exhaust Y pipe to exhaust manifold

NM

50

-

50

Number

Designation

Engines 402.970, 441.980, 446.938, 457.944

BF20.00-N-1001-01D

Coolant capacity

without VOITH retarder

Liter

75...100

with VOITH retarder

Liter

95...120

Specifications for Service Products

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A