D01.30-1087-09
Shown on engine 646.985 |
1 | Bracket (for transmission 722) | 5 | Coolant hose | 9 | Exhaust manifold | ||
2 | Rail | 6 | Coolant thermostat housing | 10 | Cylinder head bolt | ||
3 | Screw | 7 | Turbocharger | 11 | Cylinder head | ||
4 | Electrical connection (with code Z42 (Approval as a passenger car) | 8 | Screw/bolt (for engine 646.984/985/989/990) |
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. | |
Danger | 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. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. | |
Danger | Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure | Keep all ignition sources out of hazard area. | |
Warning | Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | |
Topical note | Notes on self-locking nuts and bolts | ||
Notes about Common-Rail components | |||
| Remove/install | ||
1 | Drain off coolant | ||
2.1 | Remove upper section of charge air distributor | Engine 646.984/985/986 | |
2.2 | Remove charge air distributor | Engine 646.989/990 | |
3 | Remove camshaft case | ||
4 | Remove intermediate gear of high-pressure pump | ||
5 | Remove screw/bolts (3) and place rail (2) to one side | Screw/bolt, rail to cylinder head | |
6 | Disconnect electrical connection (4) | Engine 646.984/985/986/989/990 in model 906 | |
7 | Remove coolant hoses (5) on coolant thermostat housing (6) | Catch escaping coolant with rags. | |
Installation: Check clamps and coolant hoses (5) for damage. | |||
Hose clamp pliers | |||
Depending on findings | |||
| |||
Replace clamps on coolant hose(5). | |||
8 | Remove oil feed line on ATL (7) |
| |
Seal openings with suitable stop plug. | |||
Record plug | |||
9 | Remove bracket (1) for filler pipe for A/T on cylinder head (11) | Engine 646 in model 906 with transmission 722 | |
Engine 646 in model 906 with transmission 722.9Bolt, filler pipe to cylinder head | |||
Engine 646 in model 906 with transmission 722.684Bolt, filler pipe to cylinder head | |||
10.1 | Remove screw/bolts (8) on exhaust manifold (9) | Engine 646.984/985/989/990 | |
Engine 646.984/985/989/990Flange connection, exhaust manifold to turbocharger | |||
10.2 | Remove ATL (7) with exhaust manifold (9) | Engine 646.986 | |
11 | Loosen cylinder head bolts (10) and screw/bolts (arrows) in stages and remove | ||
| |||
Bolt, cylinder head to timing case cover | |||
Screw/bolt, cylinder head to crankcase | |||
12 | Remove cylinder head (11) | Use aid of helper. | |
Installation: When fitting on the cylinder head (11), pay attention to pilot bushing. | |||
13 | Reinstall detachable body components of cylinder head (11) | When replacing cylinder head (11). | |
14 | Remove cylinder head gasket | Installation: Replace cylinder head gasket. | |
| Clean | ||
15 | Clean sealing surfaces at cylinder head (11) and crankcase | ||
Loctite 7200 | |||
Loctite 7063 (400 ml) cleaning spray | |||
16 | Clean threaded holes of cylinder head bolts (10) in crankcase | Blow dirt or fluid out of the threaded holes. | |
| Check | ||
17 | Check sealing surface on cylinder head (11) | Depending on findings | |
| |||
Replace cylinder head (11) | |||
18 | Check cylinder head bolts (10) | ||
Cylinder head bolt | |||
Depending on findings | |||
| |||
Replace cylinder head bolts (10). | |||
19 | Install in the reverse order | ||
| Check | ||
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. | |
20 | Check for leak tightness with engine running | Visual inspection only. |
003 589 03 37 00
Hose clamp pliers
129 589 00 91 00
Record plug
Referenced documents
- ah0000n000101a Notes on self-locking nuts and bolts
- ah0716p000201tx Notes about Common-Rail components
- ar0100p005001a Remove sealant
- ar0130s580001sd Tightening procedure for cylinder head bolts
- ar0130s580003sd Check cylinder head bolts
- ar0510d4650sd Remove/install intermediate gear for high-pressure pump
- ar0520s6995sd Remove/install camshaft housing
- ar0940d6022sd Remove/install oil feed line for turbocharger
- ar0940d6025se Remove/install turbocharger with exhaust manifold
- ar0941d1310sd Remove/install charge air manifold
- ar0941d1310sk Remove/install charge air manifold
- ar2000d1140sd Drain coolant, fill up and check cooling system for leaks
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
- as0000z000501a 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.
- as0716z000101a Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure
- 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.