Remove/install cylinder head

AR01.30-P-5800CD

Remove/install cylinder head

23.08.2019

Engine

651 in model 204, 207, 212, 218, 221

Modification notes

23.08.2019

Note added.

Operation step 29

Shown on engine 651.911

1

Bracket

5

Screw

11

Bolts

2

Bolts

9

Screw

N14/3

Glow output stage

4

Fuel lines

10

Bracket

Shown on engine 651.911

12

Clamp

16

Bracket

18

Coolant hose

13

Screw

17

Bolts

19

Fuel filter housing

15

Bolts

Shown on engine 651.911

Y94

Quantity control valve

Shown on model 204 with engine 651.911

24

Bolts

27

Bolts

30

Tensioning rail

25

Screw

28

Dowel pins

B19/11

Temperature sensor upstream of turbocharger

26

Bolts

29

Timing chain

A

Sealed areas

50

Marking with "R" stamp

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

AS07.16-Z-0001-01A

 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.

AS00.00-Z-0002-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Disconnect ground line from battery.

Engine 651 in model 204

AR54.10-P-0003CW

Engine 651 in model 207, 212, 218

AR54.10-P-0003EW

Engine 651 in model 221

AR54.10-P-0003SX

 Do not connect no-load current retention unit.

2.1

Remove bottom sections of soundproofing.

Engine 651 in model 204, 207, 212, 218

Engine 651 in model 204.9

AR61.20-P-1105CY

Model 204.0/2/3, 207, 212, 218 with engine 651

AR94.30-P-5300EW

2.2

Remove lower engine compartment paneling.

Engine 651 in model 221
except code Z07 (Top protection)

AR61.20-P-1105SX

3

Drain off coolant.

Engine 651.9 in model 212.098/298

AR20.00-P-1142EH

Engine 651 in model 204, 207

AR20.00-P-1142CW

Engine 651 in model 212 (except 212.098/298), 218, 221

AR20.00-P-1142OMA

 Installation:
Do not check the pressure of the cooling system until engine has reached its operating temperature.
Leaks can occur on the cylinder head gasket otherwise.

If the cooling and heating system is oiled up,



De-oil cooling and heating system.

AR20.00-P-1250CD

4

Remove air filter housing.

AR09.10-P-1150CD

5

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130CD

6

Unclip clamps (12) from the bracket of the front air filter housing.

7

Remove bolt (13).

 Bolt for oil line bracket

*BA09.40-P-1004-01P

8

Remove screws (15) and remove bracket of the front air filter housing.

 Screw/bolt, air filter bracket to cylinder head

*BA09.10-P-1001-01K

9

Unhook engine wiring harness from the bracket (16).

10

Remove screws (17) and remove bracket of the rear air filter housing and place to one side with the differential pressure sensor.

 Screw/bolt, air filter bracket to cylinder head

*BA09.10-P-1001-01K

11

Remove rear lifting lug from the cylinder head and place lifting lug with oil dipstick tube to one side.

 Lifting eye or bracket for glow output stage to cylinder head

*BA01.30-P-1004-01V

12

Remove screws (24).

 Installation: Install new screws (24) and seal.

 Flange connection, exhaust manifold to exhaust gas turbocharger

*BA09.40-P-1001-01P

13

Remove temperature sensor upstream of the exhaust gas turbocharger (B19/11).

AR07.04-P-0071CD

14

Remove fuel filter.



Engine 651 in model 204

AP47.20-P-0780CWD



Engine 651 in model 207, 212, 218

AP47.20-P-0780EWD



Engine 651 in model 221

AP47.20-P-0780SXI

15

Remove screw (9) and remove ground line.

 Bolt, engine wiring harness ground connection (W11) for glow output stage (GZE) to cylinder head

*BA15.18-P-1004-01C

16

Remove screws (11) and place bracket (10) with glow output stage (N14/3) to one side.

 Lifting eye or bracket for glow output stage to cylinder head

*BA01.30-P-1004-01V

17

Remove the exhaust gas recirculation valve.

AR14.20-P-7662CD

18

Remove screws (2) and remove bracket (1) for the exhaust gas recirculation cooler.

 Bolt, Y-support brace to cylinder head

*BA14.20-P-1007-01K

19

Remove screw (5) and place fuel lines (4) to one side.

 M61

*BA00.10-P-1002-04A

20

Remove the coolant thermostat.

Engine 651.9 in model 212.098/298

AR20.10-P-2460EH

Engine 651 in model 204, 207, 212 (except 212.098/298), 218, 221

AR20.10-P-2460CD

21

Disconnect coolant hose (18) from the fuel filter housing (19).

 Hose clamp pliers

*003589033700

22

Release and disconnect electrical connector at quantity control valve (Y94).

23

Remove high-pressure line.

AR07.16-P-1080CD

24

Remove glow plugs.

AR15.20-P-4111CD

25

Turn engine at the crankshaft in the direction of engine rotation using the counterholder and place the piston for cylinder 1 at top dead center (ignition TDC).

 The 0° marking on belt pulley/vibration damper must align with the marking on crankcase.

 Counterholder

*651589004000

26

Remove hydraulic valve play compensation elements.

AR05.00-P-2011CD

27

Remove screws (25, 26).

 Bolt, cylinder head to timing case cover

*BA01.30-P-1001-01V

28

Loosen screws (27) in stages in reverse order of the tightening procedure and remove.

AR01.30-P-5800-01CD


Remove screw/bolts (27) only for a cooled engine.
This avoids stresses in the cylinder head.

 Installation: Screws/bolts (27) must be lubricated at thread and contact surface and then inserted. Observe tightening procedure. It is not necessary to retighten the screw/bolts (27).

 Bolt, cylinder head to timing case cover

*BA01.30-P-1001-01V

 Screw/bolt, cylinder head to crankcase

*BA01.30-P-1002-01V

29

Remove cylinder head from the crankcase.

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

General information on checking valves, valve seats and valve guides

AH05.30-P-1000-02SZ

 Installation: Secure timing chain (29) on tensioning rail (30) for better assembly using a cable tie.

 Installation: Observe dowel pins (28) for fixing the cylinder head in place.

 Installation: Replace cylinder head gasket.

 Installation: Apply a sealing bead in the sealing areas (A) between the timing case and crankcase.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500



Clean

30

Blow out threaded holes on the crankcase with compressed air.

31

Clean sealing surfaces on the cylinder head and on the crankcase with a lint-free cloth.


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.



Check

32

Check sealing surfaces on the crankcase for cracks and unevenness.

 Sealing surfaces on crankcase must not be reworked.

If any problems are found



Replace crankcase.

33

Check sealing surfaces on the cylinder head for cracks and unevenness.

 Sealing surfaces on cylinder head must not be reworked.

If any problems are found,



Replace cylinder head.

34

Check whether a repair crankcase has been installed with the repair piston.

 If an "R" (50) is stamped on the cylinder head contact surface, the corresponding repair cylinder head gasket must be ordered in EPC.

35

Check length of the screws (27).

AR01.30-P-5800-03T

Cylinder head bolt

*BE01.30-P-1001-04H

If any problems are found,



Replace screws (27).

36

Install in the reverse order.



Check

37

Check engine oil level, correct if necessary.



AP18.00-P-1811MP

 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.

AS00.00-Z-0005-01A

38

Check engine and fuel system for leak tightness with the engine running.

Cylinder head/cylinder head bolts

Number

Designation

Engine 651

BE01.30-P-1001-04H

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

226 (0,5)

Max. length (L)

mm

227,5

For picture, see

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Tightening torques, cylinder head

Number

Designation

Engine 651

BA01.30-P-1001-01V

Bolt, cylinder head to timing case cover

M8

Nm

20

 Tightening torques, cylinder head

Number

Designation

Engine 651

BA01.30-P-1002-01V

Screw/bolt, cylinder head to crankcase

M12

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

Stage 6

°

90

 Tightening torques, cylinder head

Number

Designation

Engine 651

BA01.30-P-1004-01V

Lifting eye or bracket for glow output stage to cylinder head

Nm

20

 Air filter

Number

Designation

Engine 651

BA09.10-P-1001-01K

Screw/bolt, air filter bracket to cylinder head

Nm

9

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1001-01P

Flange connection, exhaust manifold to exhaust gas turbocharger

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1004-01P

Bolt for oil line bracket

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1007-01K

Bolt, Y-support brace to cylinder head

Nm

9

 Engine wiring harness

Number

Designation

Engine 651

BA15.18-P-1004-01C

Bolt, engine wiring harness ground connection (W11) for glow output stage (GZE) to cylinder head

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10