Shown on engine 541.9 |
1 | Cylinder head seal |
2 | Cylinder head |
3 | Injection line |
4 | Leak fuel line |
5 | Push rod |
6 | Rocker arm assembly |
7 | Valve bridge |
8 | Cylinder head bolt |
9 | Constant throttle line |
10 | Constant throttle line |
11 | Seal |
12 | Exhaust manifold |
13 | Spring pin |
14 | Centering sleeves or dowel pins |
L | Shank length |
W01.30-1038-06
| Remove | ||
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. | |
Topical note | Notes on coolant | ||
1 | Switch off ignition | ||
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
2 | Tilt cab | ||
Topical note | Notes on tilting the cab | ||
3 | Remove right or left noise encapsulation from top frame | ||
4 | Partially drain coolant at radiator | ||
5 | Remove charge air manifold | ||
6 | Remove clamps of the steering oil return line and steering oil pressure line from the brackets | Only when removing the cylinder heads (2) from the left side of the engine. | |
7 | Remove leak fuel line (4) from the affected cylinder head (2) | In addition, remove the leak fuel line (4) from the cylinder head (2) in front of the affected cylinder head and push leak fuel line (4) away. | |
8 | Remove injection line (3) from the affected cylinder head (2) | ||
9 | Remove cylinder head cover from the affected cylinder head (2) | ||
10 | Remove rocker arm assembly (6) from the affected cylinder head (2) | ||
11 | Remove valve bridges (7) | ||
12 | Pull out pushrods (5) | Turn pushrods (5) while pulling out so that they can release in the roller tappets and the roller tappets are not pulled out of the cylinder crankcase. | |
13 | Remove constant throttle lines (9, 10) from the affected cylinder head (2) | ||
14 | Remove exhaust manifold (12) of the affected cylinder head bank |
| |
Engine 542.9 | |||
15 | Remove cylinder head bolts (8) and remove cylinder head (2) | | |
16 | Remove cylinder head gasket (1) | ||
17 | Clean cylinder head (2) | Only scrape off cylinder head sealing surface while cleaning. | |
18 | Seal all bores on the contact surface of the cylinder crankcase with fabricated stop plugs | ||
| |||
| Check | ||
19 | Check cylinder head sealing surface and cylinder head gasket (1) for cracks and damage | ||
If the cylinder head (2) is warped or if the cylinder head gasket (1) is not gas-tight, it is recommended to install a new cylinder head (2) with inductive hardening if the cylinder head (2) does not have inductive hardening. If the cylinder head (2) does have inductive hardening, the cylinder head (2) must be replaced. | |||
Height of cylinder head | |||
Permissible variation of flatness of lower separating surface | |||
20 | Clean and check contact surfaces of the cylinder crankcase and cylinder head (2) | | |
Only scrape off seal and paint residues on the contact surface; do not rub with emery cloth. | |||
21 | Check cylinder head bolts (8) | If the permissible shank length (L) is exceeded, the affected cylinder head bolt (8) must be replaced. | |
Cylinder head bolts M182 | |||
22 | Check centering sleeves or dowel pins (14) for damage | If a centering sleeve or dowel pin (14) is damaged, both centering sleeves or dowel pins (14) must be pulled out with pliers and replaced with new dowel pins (14). | |
23 | Carefully pull out stop plugs from all bores of the cylinder crankcase | ||
24 | Check seating of the roller tappets in the cylinder crankcase | ||
| Install | ||
25 | Position new cylinder head gasket (1) over the centering sleeves or dowel pins (14) on the contact surface of the cylinder crankcase | ||
| |||
Observe installation position of the cylinder head gasket (1). | |||
26 | Position cylinder head (2) over the centering sleeves or dowel pins (14) on the cylinder head gasket (1) | ||
| |||
27 | Tighten cylinder head (2) | ||
Oil contact surface, thread, and stem of the cylinder head bolts (8) with engine oil. | |||
Cylinder head bolts M182 | |||
Cylinder head bolt to crankcase | |||
Socket wrench bit | |||
28 | Install exhaust manifold (12) |
| |
Engine 542.9 | |||
29 | Attach constant throttle lines (9, 10) to the cylinder head (2) | Install new sealing rings. | |
Air line of constant throttle to cylinder head | |||
30 | Install push rods (5) | Oil pushrods (5) with engine oil and ensure that they are seated correctly in the roller tappets. | |
31 | Insert valve bridges (7) | ||
32 | Install rocker arm assembly (6) | ||
33 | Install cylinder head cover | ||
34 | Attach leak fuel line (4) | Install new sealing rings. | |
Leak fuel line to cylinder head | |||
35 | Install injection line (3) | ||
36 | Install charge air manifold | ||
37 | Attach clamps of the steering oil return line and steering oil pressure line to the brackets | Only for cylinder heads (2) on the left side of the engine. | |
38 | Perform additional inspection work on the cylinder head (2) and on the cylinder head gasket (1) after engine repair | ||
39 | Check engine oil level with oil dipstick or on the display; correct if necessary | ||
Notes on engine oil | |||
Observe engine oil grade set in maintenance system or Specifications for Operating Fluids. | |||
40 | Check engine oil level in the reservoir of the automatic engine oil refill and pour in up to the maximum mark if necessary | ||
Notes on engine oil | |||
Only for code (MB7) automatic engine oil replenishment. | |||
41 | Pour in coolant | ||
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. | |
42 | Start engine, bleed fuel system, observe oil pressure display with the engine running at idle speed, and perform engine test run | Do not rev up engine before oil pressure is indicated. After approx. 10 s, the oil pressure gage must display the oil pressure. | |
Engines 541.9, 542.9Engine oil pressure at | |||
The fuel system is bled automatically. If engine fails to start or only runs for a brief period: | |||
| |||
Purge fuel system by hand. | |||
| |||
43 | Turn off engine and check for leak tightness in the area of cylinder head (2) | Visual inspection. | |
44 | Install noise encapsulation on the top right or left frame | ||
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
45 | Tilt back cab | ||
Topical note | Notes on tilting the cab |
422 589 02 09 00
Socket wrench bit
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