Remove/install cylinder head

AR01.30-W-5800C

Remove/install cylinder head

04.12.2019

Engine

457.9 in model 374, 375, 940, 942, 943, 944, 958

Modification notes

20.04.2006

Permissible deviation in flatness of bottom contact surface.

BE01.30-N-1002-02Q

1

Cylinder head

2

Constant throttle line

3

Constant throttle line

4

Coolant bleed line

5

Cylinder head bolt

6

Rocker arm assembly

7

Valve bridge

8

Leak fuel line

9

Push rod

10

Cylinder head seal

11

Centering sleeves

L

Shank length

Shown for code MS4 (BlueTec 4) or for code MS5 (BlueTec 5)

2

Constant throttle line

12

Clip

13

Screw

14

Clamp (only with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5))

15

Compressed air line (only for code MS4 (BlueTec 4) or for code MS5 (BlueTec 5))

16

Coolant line (only for code MS4 (BlueTec 4) or for code MS5 (BlueTec 5))

17

Lifting eye at the rear

Pfeil

Angles



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.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

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.

AS60.80-Z-0001-01A

2

Tilt cab

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

3

Remove soundproofing from frame on the upper left and right

4

Partially drain coolant at radiator

AR20.00-W-1142B

5

Remove exhaust manifold

Vehicles without code MZ4 (turbobrake)

AR14.10-W-3915D

Vehicles with code MZ4 (turbobrake)

AR14.10-W-3915DA

6

Remove coolant bleed line (4) from all cylinder heads (1)

 Bind coolant bleed line (4) to the side.

7

Remove clamp (12) of constant throttle line (2) at rear lifting eye (17).

8

Remove constant throttle line (2) from connection fitting.

9

Remove clamp (14) of compressed-air line (15) and coolant line (16) at rear lifting eye (17).

 Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5) if the cylinder head (1) of the sixth cylinder is being removed.

10

Release screws (13) on the rear lifting eye (17) and push rear lifting eye (17) away from cylinder head (1) until the angle piece (arrow) is no longer in contact with the cylinder head (1).

 Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5) if the cylinder head (1) of the sixth cylinder is being removed.
Do not bend or damage lines attached to rear lifting eye (17).

11

Remove constant throttle line (3) at all cylinder heads (1).

12

Remove charge air manifold

AR09.41-W-8681D

13

Remove injection line from affected cylinder head (1).

AR07.15-W-9235C

14

Remove leak fuel line (8) from affected cylinder head (1).

 In addition, remove leak fuel line (8) at cylinder head (1) located in front of affected cylinder head and push away leak fuel line (8).

15

Remove cylinder head cover at affected cylinder head (1).

AR01.20-W-5014C

16

Remove rocker arm assembly (6) at affected cylinder head (1).

AR05.00-W-5521D

17

Remove valve bridges (7)

18

Remove push rods (9)

19

Unscrew cylinder head bolts (5) and remove cylinder head (1)

 Place cylinder head (1) to the side so that the installed nozzle holder combination is not damaged.

20

Remove cylinder head gasket (10)

21

Clean cylinder head (1)

 Only scrape off cylinder head sealing surface during cleaning.

22

Close off all bores on cylinder crankcase contact surface using fabricated stop plugs



WF58.50-W-0100-04A



Check

23

Check cylinder head sealing surface for cracks and damage as well as the cylinder head gasket (10)

AR01.30-W-5800-15A

 If the cylinder head gasket (10) is not gastight, replace the cylinder head gasket (10).

Height of cylinder head

*BE01.30-N-1001-02Q

Permissible variation of flatness of lower separating surface

*BE01.30-N-1002-02Q

If the cylinder head (1) is warped:



If the cylinder head (1) does not have inductive hardening, face-grind the cylinder head contact surface. However, we recommend installing a new cylinder head (1) with inductive hardening.

AR01.30-W-7162C

 If the cylinder head (1) has inductive hardening, replace the cylinder head (1).

24

Clean and check the contact surface of the cylinder crankcase


No dirt must find its way into the bores for engine oil, coolant, push rods (9) and cylinder head bolts (5) or the cylinder liner.
Otherwise, engine damage can occur.

 Only scrape off sealant and paint residue from the contact surface.

25

Check cylinder head bolts (5)

 If the permissible shank length (L) is exceeded the cylinder head bolt (5) involved must be replaced.

Cylinder head boltsM15x2

*BE01.30-N-1001-01L

26

Perform a visual inspection of the push rods (9)

 If the pan or ball head is deformed or damaged, the push rod in question (9) must be replaced.



Install

27

Pull stop plug carefully out of all bores of the cylinder crankcase

28

Place the new cylinder head gasket (10) onto the contact surface of the cylinder crankcase via the centering sleeves (11)

 Observe installation position of cylinder head gasket (10).

29

Mount cylinder head (1) onto cylinder head gasket (10) via centering sleeves (11).

30

Tighten the cylinder head (1)

AR01.30-W-5800-07C

 Oil the contact surface, thread and shank of the cylinder head bolts (5) with engine oil.
Comply with the tightening specification for the cylinder head bolts (5).

Cylinder head boltsM15x2

*BE01.30-N-1001-01L

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01S

 Wrench socket

*422589010900

31

Install push rods (9)

 Oil the push rods (9) with engine oil and ensure they are seated correctly in the roller tappet.

32

Insert valve bridges (7).

33

Install rocker arm assembly (6).

AR05.00-W-5521D

34

Install cylinder head cover

AR01.20-W-5014C

35

Attach leak fuel line (8)

 Banjo bolt of leak oil pipe on cylinder head

*BA01.30-N-1005-01S

36

Install injection line

AR07.15-W-9235C

37

Install charge air manifold

AR09.41-W-8681D

38

Attach constant throttle line (3)

 Banjo bolt, constant throttle pressure line to cylinder head

*BA01.30-N-1004-01S

39

Tighten screws (13) on rear lifting eye (17).

 Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5) if the cylinder head (1) of the sixth cylinder has been removed.

 Screw/bolt, rear lifting eyes to crankcase

*BA22.10-N-1007-01D

40

Install clamp (14) of compressed-air line (15) and coolant line (16) at rear lifting eye (17).

 Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5) if the cylinder head (1) of the sixth cylinder has been removed.

 Screw/bolt, clamp to rear lifting eye

*BA22.10-N-1009-01D

41

Attach constant throttle line (2) to connection fitting.

42

Attach clamp (12) of constant throttle line (2) to rear lifting eye (17).

 Screw/bolt, clamp to rear lifting eye

*BA22.10-N-1009-01D

43

Attach coolant bleed line (4)

 Connection fitting, coolant vent line to cylinder head

*BA01.30-N-1002-01S

 Banjo bolt, coolant vent line to connection fitting

*BA01.30-N-1003-01S

44

Install exhaust manifold

Vehicles without code MZ4 (turbobrake)

AR14.10-W-3915D

Vehicles with code MZ4 (turbobrake)

AR14.10-W-3915DA

45

Perform additional inspection work after engine repair at cylinder head (1) and at cylinder head gasket (10).

AR01.10-W-0003A

46

Check engine oil level with oil dipstick or on display, add oil if necessary

Notes on engine oil

AH18.00-N-0101-01HA

 Observe oil grade set in maintenance system or Specifications for Operating Fluids.

47

Pour in coolant

AR20.00-W-1142B

 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

48

Start engine and allow to run in idle for 10 s until the oil pressure has built up, then run the engine at varying speeds

 The fuel system is bled automatically.

If engine fails to start or only runs for a brief period:



Purge fuel system by hand.

AR47.00-W-1720C

49

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

 Visual inspection.

50

Attach soundproofing to frame on the upper left and right

 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.

AS60.80-Z-0001-01A

51

Tilt back cab

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Check values for cylinder head bolts

Number

Designation

Engine 457.9

BE01.30-N-1001-01L

Cylinder head boltsM15x2

Length of shank when new

mm

210

Permissible shank length

mm

212

Check values for cylinder head

Number

Designation

Engine 457.9 without inductive hardening on cylinder head

Engine 457.9 with inductive hardening on cylinder head

BE01.30-N-1001-02Q

Height of cylinder head

When new

mm

113,85...114,15

113,85...114,15

After material removal

mm

113,5

-

Check values for cylinder head

Number

Designation

Engine 457.9 without inductive hardening on cylinder head

Engine 457.9 with inductive hardening on cylinder head

BE01.30-N-1002-02Q

Permissible variation of flatness of lower separating surface

Wear dimension

mm

0,1

0,1

 Cylinder head

Number

Designation

Engine 457.9

BA01.30-N-1001-01S

Screw/bolt, cylinder head to crankcase

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

Nm

100

Stage 4

Nm

200

Stage 5

°

90

Stage 6

°

90

 Cylinder head

Number

Designation

Engine 457.9

BA01.30-N-1002-01S

Connection fitting, coolant vent line to cylinder head

Nm

35

 Cylinder head

Number

Designation

Engine 457.9

BA01.30-N-1003-01S

Banjo bolt, coolant vent line to connection fitting

Nm

35

 Cylinder head

Number

Designation

Engine 457.9

BA01.30-N-1004-01S

Banjo bolt, constant throttle pressure line to cylinder head

Nm

45

 Cylinder head

Number

Designation

Engine 457.9

BA01.30-N-1005-01S

Banjo bolt of leak oil pipe on cylinder head

Nm

15

 Engine mounts, engine supports

Number

Designation

Engine 457.9

BA22.10-N-1007-01D

Screw/bolt, rear lifting eyes to crankcase

Nm

200

 Engine mounts, engine supports

Number

Designation

Engine 457.9

BA22.10-N-1009-01D

Screw/bolt, clamp to rear lifting eye

Nm

25