AR01.30-A-5800A | Remove/install cylinder head | 10.11.11 |
ENGINES 457.939 /945 /946 /949 in MODEL NAB372.124
ENGINES 457.939 /945 in MODEL NAB372.317
A01.30-0001-09
1 Banjo bolt
2 Sealing ring
3 Coolant vent line
4 Clip
5 Coolant hose
6 Fitting
7 Compressed-air line
8 Banjo bolt
16 Rocker arm assembly
17 Tappet rod
18 Valve bridge
19 Cylinder head bolt
20 Cylinder head
21 Cylinder head gasket
22 Fitting sleeve
9 Sealing ring
10 Connection fitting
11 Constant throttle pressure line
12 Banjo bolt
13 Sealing ring
14 Fuel leak line
15 Screw
| Removing | ||
Danger! | Risk of injury to skin and eyes caused by handling hot or glowing objects. | Wear safety gloves, protective clothing and safety glasses, if necessary. | |
Danger! | Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
1 | Remove engine compartment flap at rear | ||
Danger! | Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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. | |
2 | Drain and collect coolant | ||
| Notes on coolant | ||
3 | Open left rear maintenance flap | ||
4 | Disconnect ground line of battery | ||
5 | Remove air filter housing | ||
6 | Remove engine compartment flap below last row of seats | ||
7 | Remove engine brake valve fitting | ||
8 | Remove air intake hose | ||
9 | Remove bottom charge air pipe on left | ||
10 | Remove turbocharger | ||
11 | Remove exhaust manifold | ||
12 | Remove charge air manifold | ||
13 | Remove MR/PLD injection lines | ||
14 | Remove cylinder head cover | ||
15 | Detach fuel leak line (14) | ||
16 | Detach compressed air line (7) from connection fitting at cylinder 6 | ||
17 | Detach constant throttle pressure line (11) | ||
18 | Detach coolant hose (5) | Slacken clamp (4). | |
19 | Detach coolant vent line (3) | ||
20 | Unbolt connection (6) | ||
21 | Remove rocker arm assembly (16), valve bridges (18) and tappet rods (17) | ||
22 | Remove cylinder head bolts (19) | ||
23 | Take off cylinder head (20) | Always place cylinder head down to the side when injection nozzle installed. The injection nozzle projects at the bottom of cylinder head. | |
24 | Remove cylinder head gasket (21) | ||
| Checking | ||
25 | Inspect crankcase contact surface for damage and corrosion points. | Face-grind if there are complaints: | |
Check/face-grind crankcase contact surfaces | |||
26 | Inspect flatness of crankcase separating surface over the entire length and also diagonally | It must not be possible to insert the feeler gage between crankcase contact surface and knife-edge straightedge. If inspection is carried out in the transverse direction, the permissible variation stated is merely a reference value and cannot be measured. | |
Steel rule | |||
Straightedge | |||
Face-grind if there are complaints: | |||
Machine crankcase contact surface | |||
27 | Check flatness of cylinder head | ||
Steel rule | |||
Straightedge | |||
28 | Inspect length of shank of cylinder head bolts (19) | Replace cylinder head bolts, if necessary. | |
| Install | ||
29 | Fit on new cylinder head gasket (21) | Fit new cylinder head gasket (21) over dowel sleeves (22) onto plane face of crankcase. The part number of cylinder head gasket must be facing up. Pay attention to thickness of cylinder head gasket. | |
30 | Place the cylinder head (20) in position | | |
31 | Screw in cylinder head bolts (19) | Lightly lubricate cylinder head bolts (19). | |
Observe tightening instructions. | |||
| |||
32 | Install rocker arm assembly (16), valve bridges (18) and tappet rods (17) | Check whether push rods are seated properly in tappets. Lubricate tappet rod sockets and balls with engine oil. | |
Set valve clearance. | |||
33 | Bolt on connection (6) | Replace sealing rings (2). | |
| |||
34 | Attach coolant vent line (3) | Replace sealing rings (2). | |
| |||
35 | Attach coolant hose (5) | ||
36 | Fasten clamp (4) | ||
37 | Attach constant throttle pressure line (11) | Replace sealing rings (9). | |
| |||
38 | Screw compressed air line (7) at connection fitting onto cylinder 6 | ||
39 | Attach fuel leak line (14) | Replace sealing rings (13). The connections of the line fittings must be aligned. | |
| |||
40 | Install cylinder head cover | ||
41 | Install MR/PLD injection lines | ||
42 | Install charge air manifold | ||
43 | Install exhaust manifold | ||
44 | Install turbocharger | ||
45 | Install bottom charge air pipe on the left | ||
46 | Install air intake hose | ||
47 | Install engine brake valve fitting | ||
48 | Install engine compartment flap below last seat row | ||
49 | Install air filter housing | ||
50 | Remove ground cable for battery | ||
51 | Pour in coolant | ||
| Notes on coolant | ||
52 | Close left rear maintenance flap | ||
53 | Install engine compartment flap at the rear |
Check values for cylinder head bolts
Check values for cylinder head
Number | Designation | Engine 457.9 | ||
BE01.30-N-1002-02K | Permissible variation in flatness of lower separating surface in a longitudinal direction | Over a length of 150 mm | mm | 0.015 |
Check values of crankcase
Number | Designation | Engine 457.9 | ||
BE01.40-N-1001-02I | Crankcase - flatness of separating surface | over a length of 170 mm in longitudinal and transverse direction | mm | 0.02 |
Cylinder head
Number | Designation | Engine 457.9 | ||
BA01.30-N-1001-01J | Cylinder head bolt to crankcase | Stage 1 | Nm | 10 |
Stage 2 | Nm | 50 | ||
Stage 3 | Nm | 100 | ||
Stage 4 | Nm | 200 | ||
Stage 5 | ° | 90 | ||
Stage 6 | ° | 90 | ||
See picture | -̧ | |||
BA01.30-N-1002-01J | Connection fitting, coolant vent line to cylinder head | Nm | 35 | |
BA01.30-N-1003-01J | Banjo bolt, coolant vent line to connection fitting | Nm | 35 | |
BA01.30-N-1004-01J | Banjo bolt, constant throttle pressure line to cylinder head | Nm | 45 | |
BA01.30-N-1005-01J | Banjo bolt, fuel leak line to cylinder head | Nm | 15 | |
Referenced documents
- ah2000n208001a Notes on coolant
- ap0530a0560a Set valve clearance
- ar0120a5014a Remove/install cylinder head cover
- ar0130a580007a Tightening specifications for cylinder head bolts
- ar0130a580012a Check flatness of cylinder head
- ar0130a7162a Check/face-grind cylinder head contact surfaces
- ar0500a5521a Remove/install rocker arm assembly
- ar0715a9235a Remove/install MR/PLD injection lines
- ar0910a1150a Remove/install air filter housing
- ar0910a8030a Remove/install air intake hose
- ar0940a6020a Remove/install turbocharger
- ar0941a1316a Remove/install left bottom charge air pipe
- ar0941a8681a Remove, install charge air manifold
- ar1410a3915a Remove/install exhaust manifold
- ar1415a6302a Remove, install engine brake flap fitting
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
- as4700z000101a 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.