Remove/install cylinder head

AR01.30-G-5800A

Remove/install cylinder head

24.10.05

 

Remove/install

1

Remove intake hose (26) with intake tube

2

Remove charge air hose (23) at turbocharger (21)

3

Remove air hose to charge air distribution pipe (1)

4

Unscrew oil return (24) from turbocharger (21) on crankcase

 Installation: Replace O-rings and gaskets

5

Unbolt oil pressure line (22) at turbocharger (21) at top and bottom



*000589680300

6

Unbolt exhaust bracket at transmission

7

Unbolt exhaust pipe at turbocharger (21)



Use new nuts.

*BA09.40-N-1001-01L

8

Detach vacuum lines at vacuum unit of exhaust gas recirculation and boost pressure

9

Remove charge air distribution pipe (1)

10

Remove oil filter housing (5)

11

Detach coolant hoses at engine side

12

Take off fuel filter (8) together with bracket and lines connected, place to the side

13

Detach fuel lines

 Set of plugs

 Seal fuel lines with plugs.

*129589009100

14

Position engine to markings for basic setting of timing

AR05.20-G-6010A

15

Install retaining lock for locking crankshaft in basic position

AR03.30-G-5000A

16

Remove tensioning device (6)

AR13.25-G-3200A

17

Remove pulley (7)

 So that bottom slide rail pin is accessible.

18

Detach vacuum line at the vacuum pump (9)

19

Detach upper generator and pivot downward

20

Remove chain tensioner

AR05.10-G-7800A

21

Remove injection lines

AR07.13-G-9230A

22

Remove engine wiring harness from cylinder head

23

Remove cylinder head cover (2)

24

Remove slide rail

 Installation: Install slide rail (10) with oblong hole pointing down.

AR05.10-G-8432A



*116589013400



*116589203300

25

Unscrew hexagon socket bolts (28) in chain housing



*BA01.30-N-1003-01N



*116589030700

26

Remove camshaft sprocket (4)



*BA05.20-N-1001-01I

27

Remove camshaft (3)

 Pay attention to diagram for slackening and tightening the bearing caps!

AR05.20-G-6292A

28

Detach leak oil lines (31) completely at injection nozzles

 So that cylinder head bolts (29) are accessible.

29

Detach/remove cylinder head bolts (29) in increments

 Tightening diagram of cylinder head bolts.  Slacken cylinder head bolts in the reverse order of the tightening diagram only once engine has cooled down.

AR01.30-G-5800-01A



 Installation: It is not necessary to retighten the cylinder head bolts (29).

 Oil cylinder head bolts (29) on thread and head contact surface, insert, tighten in increments.

*BA01.30-N-1002-01N



*601589001000

30

Check cylinder head bolts (29)

AR01.30-G-5800-03A



*BE01.30-N-1001-01K

31

Screw retaining bracket (30) to cylinder head (32)



 Screw on front bracket (30) into left hole of first camshaft bearing cap mounting. Screw on rear bracket (30) into right hole of sixth camshaft bearing cap mounting.

*119589014000

32

Hook engine hoist into mount (30), remove cylinder head (32)



 Installation: Lay new cylinder head gasket (33) onto crankcase.
When fitting, observe fitted sleeves (34) when fastening cylinder head.

 If timing case cover and cylinder are removed at the same time, the setting of the injection pump is altered.

*WE58.40-Z-1012-11A

Inspect start of injection, set.

AR07.13-G-8430A

33

Clean sealing surfaces, inspect

34

Clean threaded holes of cylinder head bolts (29)

 Free from oil and water

35

Install in the reverse order

36

Inspect cooling system for leaks

Danger!

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

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

AS00.00-Z-0005-01A

37

Run engine and inspect for leaks

38

Read out fault memory and clear.

 Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work. Encode radio. Perform actuation.

Number

Designation

Engine
602.981

BE01.30-N-1001-01K

Cylinder head bolt

Thread diameter

M

10

Length (L) when new

mm

80/ 102/ 115

Length (L)

mm

83.6 / 105.6 / 118.6

See picture

AR01.30-G-5800-03A

Number

Designation

Engine
602.981

BA01.30-N-1001-01N

Threaded ring for prechamber in cylinder head

Nm

-

BA01.30-N-1002-01N

Cylinder head to crankcase

M10

Stage 1

Nm

10

Stage 2

Nm

35

Stage 3

°

90

Stage 4

°

90

BA01.30-N-1003-01N

Cylinder head to timing case cover

M8

Nm

25

BA01.30-N-1004-01N

Bolt in chain housing

Nm

25

BA01.30-N-1006-01N

Bolt connecting dipstick guide tube to fuel filter

Nm

10

Number

Designation

Engine
602.981

BA05.20-N-1001-01I

Camshaft sprocket/flange shaft to camshaft

Stage 1

Nm

25

Stage 2

°

90

Number

Designation

Engine 602.981

BA09.40-N-1001-01L

Bolt for flange connection of turbocharger/front exhaust pipe

Nm

25

Number

Designation

Engine 602.981

BA13.25-N-1001-01N

Shock absorber to cylinder head

Nm

25

WE58.40-Z-1012-11A

Load regulator (engine hoist), self-locking