AR01.30-I-5800A | Removing/installing the cylinder head | 14.2.12 |
ENGINE 384.907 in MODEL 397
ENGINES 384.906 /907 in MODEL 684
N01.30-2044-09
1 Cylinder head cover
2 Bolt
3 Gasket
4 Bolt
5 Bolt
6 Rocker arm shaft
7 Cylinder head bolt
8 Tappet rod
9 Cylinder head
10 Cylinder head gasket
11 Injection lines
12 Gasket
13 Thermostat housing
14 Gaskets
15 Screw connection
16 Vent line
17 Electric cable (temperature sensor)
18 Hydraulic line
19 Hydraulic line
20 Power steering pump
21 V-belt
22 V-belt tensioning device
23 Carrier
24 Installation hook
N01.30-2045-09
25 Charge pressure line
26 Intake manifold
27 Gasket
28 Bolt
29 Exhaust manifold
30 Gasket
31 Washer
32 Bolt
33 Turbocharger exhaust manifold
34 Front exhaust pipe
35 Oil return line (turbocharger)
36 Hose clamp
37 Turbocharger
38 Air intake pipe
39 Bleed hose
40 Oil pressure line (turbocharger)
41 Banjo bolt
| Removing | ||
Danger! | Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries | No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers. | |
1 | Disconnect ground cable | ||
Danger! | Risk of injury caused by being caught or pinched as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut. | |
2 | Tilt cab | See owner's manual. | |
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. | |
3 | Drain coolant and collect | ||
4 | Remove radiator | ||
5 | Detach vent hose (39) | ||
6 | Detach air intake hose (38) | ||
7 | Take off vent line (16) | ||
8 | Detach electric cable (17) | ||
9 | Detach coolant hoses on coolant thermostat housing (13) | ||
10 | Detach coolant thermostat housing (13) and remove gasket (12) | ||
11 | Take out screw connection (15) and take off gaskets (14) | ||
Danger! | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning caused by swallowing hydraulic fluid. | Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses. | |
12 | Detach hydraulic hoses (18, 19) at power steering pump (20) | Catch the emerging hydraulic fluid in a container. | |
13 | Slacken V-belt (21) and take off | ||
14 | Detach V-belt tensioning device (22) | ||
15 | Remove power steering pump (20) | ||
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 contact with fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
16 | Detach fuel leak line at connection on cylinder 4 | ||
17 | Detach fuel supply line and fuel leak line at fuel suction pump | ||
18 | Detach fuel return line at fuel filter | ||
19 | Detach fuel filter and fuel suction pump together with prefilter and place to the side | ||
20 | Remove cylinder head cover (1) | ||
21 | Remove installation hook (24) and support (23) | ||
22 | Detach injection lines (11) at fuel injection pump | | |
Danger! | Risk of injury to skin and eyes from handling hot or glowing objects. | Wear safety gloves, protective clothing and safety glasses, if necessary. | |
23 | Detach front exhaust pipe (34) at turbocharger exhaust manifold (33) | ||
24 | Remove turbocharger exhaust manifold (33) | ||
25 | Detach charge pressure line (25) | ||
26 | Slacken hose clamp (36) for oil return line (35) | ||
27 | Detach oil pressure line (40) at turbocharger and take off gasket | ||
28 | Unscrew banjo bolt (41) for oil pressure line (40) on crankcase | ||
29 | Remove oil pressure line (40) | ||
30 | Remove bolts (32). | ||
31 | Remove exhaust manifold (29) together with turbocharger (37) | Seal openings of turbocharger with plugs. | |
32 | Remove bolts (28) | ||
33 | Remove intake manifold (26) | ||
34 | Unscrew hexagon bolts (4, 5) and take off rocker arm shaft (6) | ||
35 | Pull out tappet rods (8) | Turn tappet rods for this step so that they detach from the valve tappets. | |
36 | Unscrew cylinder head bolts (7) | Pay attention to slackening diagram. | |
37 | Turn handles into the threaded holes for the bolts attaching the rocker arm shaft | | |
38 | Remove cylinder head (9) and take off cylinder head gasket (10) | When placing down cylinder head, ensure that the injection nozzles are not damaged and the injection lines are not bent. | |
| Installing | ||
39 | Remove combustion residues at the plane faces of the cylinder head and of the crankcase, blow out threaded holes with compressed air | ||
40 | Inspect plane face of cylinder head and of crankcase for flatness and porous bits | ||
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41 | Inspect cylinder head bolts (7) | Hexagon bolts must always be replaced with twelve-point head bolts. | |
42 | Fit on new cylinder head gasket (10) | Pay attention to dowel pins for fixing cylinder head gasket. | |
The side of the cylinder head gasket marked with "OBEN" or "TOP" must always be pointing upwards. | |||
43 | Install cylinder head (9) | Pay attention to dowel pins for fixing cylinder head. | |
44 | Unscrew handles | | |
45 | Screw in cylinder head bolts (7) | Moisten cylinder head bolts with oil. | |
Pay attention to tightening diagram and tightening instructions of cylinder head bolts: | |||
Tightening instructions for cylinder head bolts. | |||
46 | Oil tappet rods (8) and insert | When inserting, ensure that the tappet rods are properly seated in the valve tappets. | |
47 | Fit on rocker arm shaft (6) and tighten fully | Pay attention of installation position of hexagon bolts (4, 5). If the hexagon bolts (4) are incorrectly installed, it is not possible to tighten the cylinder head cover fully. | |
| |||
48 | Install intake manifold (26) | Replace gaskets. The side of the gaskets marked with "TOP" must be pointing up. | |
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49 | Remove plugs at turbocharger | ||
50 | Install exhaust manifold (29) together with turbocharger (37) | Replace gaskets. Inspect bolts, install new bolts if necessary. | |
Coat hexagon bolts with temperature-resistant lubricating paste. | |||
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51 | Attach oil pressure line (40) to turbocharger | Install new gasket. Replace hexagon bolts. Fill housing of turbocharger with engine oil. | |
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52 | Attach oil pressure line (40) to crankcase | Replace gaskets. | |
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53 | Attach hose clamp (36) of oil return line (35) | Inspect hose clamp, install new clamp if necessary. | |
54 | Attach charge pressure line (25) | Replace gaskets. | |
55 | Install exhaust manifold for turbocharger (33) | Replace self-locking nuts. | |
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56 | Attach front exhaust pipe (34) to exhaust manifold of turbocharger (33) | Replace self-locking nuts. Inspect bolts, install new bolts if necessary. | |
| |||
57 | Attach installation hook (24) and support (23) | ||
58 | Attach injection lines (11) to injection pump | | |
| |||
59 | Attach fuel filter and fuel suction pump together with prefilter | ||
60 | Install power steering pump (20) | ||
61 | Attach hydraulic hoses (18, 19) to power steering pump (20) | ||
62 | Attach tensioning device (22) of V-belt | ||
63 | Install V-belt (21) | ||
64 | Attach fuel return line to fuel filter | Replace gaskets. | |
65 | Attach fuel supply line and fuel leak line to fuel suction pump | Replace gaskets. Secure banjo Bolt for fuel supply line with Loctite 221. | |
66 | Push fuel leak line onto connection of cylinder 4 | ||
67 | Screw in screw connection (15) | Install new screw connection (15). Replace gaskets (14). | |
68 | Attach coolant thermostat housing (13) | Replace gasket (12). | |
| |||
69 | Attach vent lines (16) | Inspect hose clamp, install new clamp if necessary. | |
70 | Attach electric cable (17) | ||
71 | Attach coolant hoses to thermostat housing (13) | Inspect hose clamp, install new clamp if necessary. | |
72 | Attach air intake hose (38) to turbocharger (37) | Inspect hose clamp, install new clamp if necessary. | |
73 | Attach vent hose (39) to air intake hose (38) | Inspect hose clamp, install new clamp if necessary. | |
74 | Install radiator. | ||
75 | Set valve clearance | ||
| Set valve clearance | ENGINE 384 in MODEL 684. | |
76 | Install cylinder head cover (1) | ||
77 | Pour in coolant | ||
| Engine cooling system - inspect fluid level, adjust to correct level | ENGINE 384 in MODEL 684. | |
78 | Inspect cooling system for leaks | ||
| Cooling and heating system - checking condition of radiator, lines and hoses | ENGINE 384 in MODEL 684. | |
79 | Connect ground cable | ||
80 | Bleed fuel system | ||
81 | Change engine oil | | |
82 | Pour in steering gear oil | ||
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. | |
83 | Run engine and inspect for leaks | Pay attention to gage for engine oil pressure. Oil pressure must be indicated after about 10 seconds. | |
84 | Bleed power steering system, inspect steering fluid level, adjust to correct level if necessary |
Engine timing - general
Injection nozzles, injection valves, lines
Intake manifold, intake manifold preheater
Exhaust manifold
Number | Designation | Engines 384.906/ | ||
BA14.10-N-1001-01I | Exhaust manifold to cylinder head | 1st stage | Nm | 60 |
2nd stage | ° | 90 | ||
BA14.10-N-1002-01I | Turbocharger to exhaust manifold | Nm | 30 | |
Oil cooling system
Number | Designation | Engine 384.906/907 | |
BA18.30-N-1002-01J | Oil pressure line to crankcase | Nm | 40 |
BA18.30-N-1003-01J | Oil pressure line to turbocharger | Nm | 25 |
Coolant pump, coolant thermostat
Number | Designation | Engines 384.906/ | |
BA20.10-N-1002-01I | Coolant thermostat housing on cylinder head | Nm | 30 |
Exhaust system
Number | Designation | Engines 384.906/ | |
BA49.10-N-1001-01E | Front exhaust pipe on exhaust manifold of turbocharger | Nm | 45 |
Engine lubrication
Number | Designation | Engine 384.906/907 | ||
BF18.00-N-1001-01H | Engine oil | Filling capacity with oil filter | Liters | 10.5 |
Liters | 7.5 | |||
Specifications for Operating Fluids | Sheet | |||
Sheet | ||||
Sheet | ||||
000 589 07 03 00
Ring wrench
Handle
312 589 01 31 00
Workshop equipment
WE58.40-Z-1001-19A | Straightedge |
Referenced documents
- ap0530i0560k Set valve clearance
- ap2000i2011k Engine cooling system - inspecting fluid level, adjusting to correct level
- ap2000i2050k Cooling and heating system - checking condition of radiator, lines and hoses
- ar0120i5014a Removing, installing cylinder head cover
- ar0130i580003a Inspecting cylinder head bolts
- ar0130i580007a Tightening specification of cylinder head bolts
- ar0130i580009a Slackening diagram for cylinder head bolts
- ar0130i7162a Checking, facing cylinder head contact surface
- ar2020i3865a Remove/install radiator
- 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.
- as0000z001301a Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.
- 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.
- as5410z000101a Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of
- as6080z000101a Risk of injury caused by body parts being pinched or crushed as cab is tilted