Remove/install cylinder head

AR01.30-B-5800D

Remove/install cylinder head

12.02.16



Remove and install

Danger!

Risk of burns due to the coolant's high temperature

De-pressurize previously the system by opening carefully the expansion tank's cap up to the first stage. Do not remove the cap, if the engine temperature is above 90 oC.

Wear the required PPEs.

AS20.00-B-0001-01A

1

Drain the cooling system

Collect the liquid:



Bus

AP20.00-B-2080A

Trucks

AP20.00-B-2080B

2

Remove the rocker arm (13)

AR05.00-B-5521B

3

Remove the tappet stems (5)

Install the stems with engine oil and pay attention to its correct seating.

4

Remove the fuel pressure tube (16) from the injection nozzle

AR07.13-B-9230A

5

Remove the fuel return tube (15) from the injection nozzle at the head

 Remove carefully the flexible return tubes (15) from the injector holders. If they are difficult to remove, cut the flexible hoses close to the connector tubes.

 The flexible return tubes must not be forced when they are removed from the injector holders. Such procedure can cause the injector holders to unfasten from the connection tubes generating leaks and allowing the penetration of air in the intake system.

6

Remove the constant throttle's tube (17)

For engines with constant throttle (TOP BRAKE).



*BA01.30-B-1002-01D

7

Remove the intake manifold (14)

AR09.20-B-1310A

8

Remove the bolts (18) from the exhaust manifold (19)

Loosen the manifold's bolts at the other heads.



*BA14.10-B-1001-01B

9

Remove the head bolts (11)



*422589000900

For the perfect seating of the head (7) joints (10), it is necessary to follow all the bolts tightening stages (11).

Install the bolts (11) with engine oil and pay attention to the prescribed tightening moment.

AR01.30-B-5800-01C



*BA01.30-B-1001-01D

10

Remover the head (7)

In order not to damage the assembled injection nozzle, put down the head supported by its lateral surface.

Install the head, fitting it perfectly in the guides (9).

11

Remove the head's joint (10)

Clean the threaded holes and check the engine's block upper face.

Replace the joint (10) and fit it perfectly in the guides (9) on the engine block. Pay attention to the joint's assemblage position (10).

The new joint has a thin involving protective layer, and therefore its careless handling or a long period out of its package, can damage it.

12

Remove the joint (8) from the exhaust manifold (19)

Install a new exhaust manifold joint (8).

Check the other joints (8) of the exhaust manifold (19) at the head.



Check

13

Measure the length (L) of the head (7) bolts (11)

Replace the bolt (11), if the maximum admissible length (L) is exceeded.

*BE01.30-B-1001-01B

14

Check whether there are cracks at the head (7)

In the case of irregularities, replace the head.

15

Check the flatness of the head's bottom face (7)

Maximum admissible flatness deviation of the bottom face.

AR01.30-B-5800-12B

Rectify the bottom face of the head, if the deviation exceeds the maximum admissible value.

AR01.30-B-7162C

16

Install in reverse order

Danger!

Risk of injuries and material damages when starting up the engine with the gearbox engaged. Risk of injuries when works are carried out with the engine heated and operating

Be sure to have the gearbox in neutral position.

Wear suitable clothing and pay attention to hot and moving engine parts.

AS00.00-B-0005-01A

17

Starting the engine

 Do not run the starter continuously for more than 10 seconds. Should the engine not start within this interval, wait for approximately 30 minutes to crank it again.

18

Check the lubricant oil pressure with the engine at idle speed

 Do not accelerate the engine until the indicator shows oil pressure. The oil pressure must be reestablished within approximately 10 seconds.

*BE18.00-B-1001-01C

19

Stop the engine after 5 minutes

20

Check for eventual leaks. Check the lubricant oil level 5 minutes after having shut down the engine

AP18.00-B-0101C

21

Check the coolant level, replenish it, if necessary

Bus.

AP20.00-B-2080A

Trucks.

AP20.00-B-2080B

Número

Denominação

Engine 475.9, 476.9

BE01.30-B-1001-01B

Maximum permissible shank length (L) of cylinder head attachment bolts

Length (A)

mm

111,0

Length (B)

mm

146,0

Length (C)

mm

170,0

Número

Denominação

Engine 475.9; 476.9

BE18.00-B-1001-01C

Engine lubricant oil pressure, minimum admissible.

Idle speed rpm.

bar

0,5

maximum rotation

bar

2,5

Número

Denominação

Engine 475.9; 476.9

BA01.30-B-1001-01D

Engine cylinder head to cylinder block.

1st stage

Nm

10

2nd stage

Nm

50

3rd stage

Nm

100

4th stage

Nm

140

5th stage

Nm

180...190

Final angular tightening

degrees

90...100

BA01.30-B-1002-01D

Exhaust brake pipe to cylinder head

B83854/01 and 02

Nm

35

Número

Denominação

Engine 475.9; 476.9

BA14.10-B-1001-01B

Exhaust manifold to cylinder head

Nm

50