Remove/install cylinder head

AR01.30-D-5800F

Remove/install cylinder head

15.12.09

 

Remove/Install

1

Remove engine

AR01.10-D-2400G

Danger!

Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. 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 bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

2

Detach transmission at engine

3

Mount engine onto assembly stand

4

Remove camshafts

AR05.20-D-6992D

5

Take out hydraulic valve clearance compensation elements (23)

6

Take off camshaft housing (1) at cylinder head

 Installation: When fitting on, pay attention to dowel sleeves (2) for locating the camshaft housing.

7

Remove high pressure pump intermediate gear (13)

AR05.10-D-4650A

8

Disconnect engine wiring harness at engine side

AR15.18-D-1000-01A

9

Take off charge air distribution pipe at cylinder head

AR09.41-D-1310A

10

Detach oil feed line (19) at cylinder head and at turbocharger (18)

Replace sealing ring(20)

 at turbocharger

*BA09.40-P-1004-01C

 at cylinder head

*BA09.40-P-1005-01C

11

Detach turbocharger (18) at exhaust manifold (16)



*BA09.40-P-1001-01C

12

Replace dipstick guide tube (5) for automatic transmission at cylinder head

13

Detach coolant pipe (21) at cylinder head and push to the side with coolant lines connect

14

Detach coolant hoses (9, 11) at coolant thermostat housing

 Inspect condition of coolant hoses and collar clamps (10, 12), replace if necessary.

15

Detach fuel line (3) at rear at rail and unclip at front at fixture

 Handle securing clip carefully.

AR47.25-P-1000-01A

 Collect escaping fuel.

Replace seal.

16

Unscrew bolts (26) of cylinder head at timing case cover

 Installation: Pay attention to tightening pattern of bolts (26) and of cylinder head bolts (25).



*BA01.30-P-1001-01M

17

Slacken cylinder head bolts (25) in stages, unscrew

 Slacken cylinder head bolts in reverse order of tightening diagram once engine has cooled down 

Tightening diagram of cylinder head bolts.

AR01.30-P-5800-01HC

 Installation: Oil and insert cylinder head bolt at thread and bolt head contact surface It is not necessary to retighten the cylinder head bolts.



*BA01.30-P-1003-01M

18

Inspect cylinder head bolts (25), replace if necessary

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

19

Take cylinder head (24) off crankcase

 Installation: Place new cylinder head gasket (27) on crankcase. When remounting the top, align with fitted bushings (28) for lining up the cylinder head.

20

Clean contact surfaces and threaded holes

 Blow out threaded holes, free of oil and water, inspect contact surfaces, if necessary 

Check the cylinder head separating surface.

21

Install in the reverse order

22

Bleed low pressure fuel circuit

AR07.16-D-0100A

23

Inspect cooling system for leaks

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-D-1010C

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

24

Inspect for oil leaks

 Run engine until warm, switch off and inspect for leaks.

 Danger!

Risk of explosion caused by ignition or explosion of fuel. Risk of injury to skin and eyes caused by fuel jets or leakage.

Keep all ignition sources out of hazard area.

Do not carry out any work on the system when it is pressurized.

AS07.16-Z-0001-01A

25

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

26

Encode radio, set clock

Number

Designation

Engine 612.981

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

max. length (L)

mm

104

For picture, see

AR01.30-P-5800-03HB

Number

Designation

Engine
612.961/962/963/965/966/967/981

BA01.30-P-1001-01M

Bolt of cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1003-01M

Bolt, cylinder head to crankcaseM12

1st stage

Nm

60

2nd stage

Nm

-

2nd stage

°

90

Step 3

°

90

4th stage

°

-

5th stage

°

-

Number

Designation

Engine 612.981

BA09.40-P-1001-01C

Flange connection of exhaust manifold to turbocharger

Nm

30

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw socket

Nm

30

Banjo bolt

Nm

18 (2)

BA09.40-P-1005-01C

Bolt of oil feed line to cylinder head

Nm

9