AR01.30-B-5800D | Remove/install cylinder head | 12.02.16 |
Cumbustion engine 475 with Vehicle 695.034, 695.051
Cumbustion engine 476 with Vehicle 695.024, 695.052
B01.30-0034-06
1 Bolt
2 Elastic washers
3 Head cover
4 Gasket
5 Tappets stem
6 intake joint
7 Cylinder head
8 Intake manifold
9 Guides
10 Cylinder head joint
11 Cylinder head bolts
12 Rocker arms bolt
13 Rocker arms
14 Intake manifold
15 Fuel return tube
16 Fuel pressure tube
17 Constant throttle's tube
18 Bolts
19 Intake manifold
L Bolt length
| 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. | |
1 | Drain the cooling system | Collect the liquid: | |
Bus | |||
Trucks | |||
2 | Remove the rocker arm (13) | ||
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 | ||
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). | |
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7 | Remove the intake manifold (14) | ||
8 | Remove the bolts (18) from the exhaust manifold (19) | Loosen the manifold's bolts at the other heads. | |
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9 | Remove the head bolts (11) | | |
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. | |||
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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. | |
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. | |
Rectify the bottom face of the head, if the deviation exceeds the maximum admissible value. | |||
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. | |
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. | |
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 | ||
21 | Check the coolant level, replenish it, if necessary | Bus. | |
Trucks. |
Check values for cylinder head bolts
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 | |||
Oil pressure
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 | |||
Cylinder head
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 | |
Exhaust manifold
422 589 00 09 00
Referenced documents
- ap1800b0101c Engine oil and oil filter change
- ap2000b2080a Replace coolant
- ap2000b2080b Replace coolant
- ar0130b580001c Tightening procedure for cylinder head bolts
- ar0130b580012b Check flatness of cylinder head
- ar0130b7162c Check/face-grind cylinder head contact surfaces
- ar0500b5521b Remove/install rocker arm assembly
- ar0713b9230a Removing and installing injection nozzles (DE)
- ar0920b1310a Remove/install intake manifold
- as0000b000501a 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.
- as2000b000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.