Remove/install cylinder head

AR01.30-S-5800CD

Remove/install cylinder head

18.02.2020

Model

415 with engine 607

1

Nut

4

Electrical connector

7

Electrical connector

2

Nut

5

Electrical connector

8

Electrical connector

3

Fuel line

6

Electrical connector

9

Electrical connector

10

Electrical connector

11

Electrical connector

12

Electrical connector

13

Vent line

14

Cylinder head

 Danger

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 poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 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.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove air-water duct

AR83.25-S-1402C

2

Remove low-pressure circuit exhaust gas recirculation positioner

AR14.20-S-1020CDN

3

Remove exhaust temperature sensor

AR07.04-S-0071CD

4

Remove engine charge air duct downstream of charge air cooler

AR09.41-S-8624CD

5

Remove diesel particulate filter below

AR49.10-S-5501CD

 To do this unscrew nuts (1, 2), loosen tensioning strap and remove differential pressure sensor from bracket.

6

Drain off coolant

AR20.00-S-1140C

7

Disconnect oil return line for ATL

AR09.40-S-6021CD

8

Remove engine stabilizer mount

AR22.10-S-1120CD

9

Remove starter

AR15.30-S-7100CD

10

Remove diesel particulate filter above

AR49.10-S-5501CD

 To do this open clamp on ATL and remove diesel particulate filter from ATL.

11

Remove fuel lines (3) at high-pressure pump

 Collect escaping fuel and seal connections.

 Record plug

*129589009100

12

Disconnect electrical connection for exhaust pressure sensor

Model 415 with engine 607
with code MO3 (Engine OM 607 DE 15 LA 81 kW (110 hp) 4000 rpm)

AR07.04-S-0040CD

13

Disconnect electrical connections (4, 5)

14

Disconnect electrical connections (6, 7, 8)

15

Disconnect electrical connection (9, 10)

16

Disconnect electrical connectors (11, 12)

17

Remove vent line (13) for transmission

18

Remove cylinder head cover

AR01.20-S-5014CD

19

Remove coolant hoses from coolant thermostat

AR20.10-S-2460CD

20

Remove vacuum hose on vacuum pump

AR43.05-S-1320CD

21

Remove glow plugs

AR15.20-S-4111CD

22

Remove toothed belt

AR05.00-S-7601CD

23

Unscrew cylinder head bolts

AR01.30-S-5800-01CD


Unfasten cylinder head bolts for a cooled engine in reverse order of the tightening procedure.
This prevents the occurrence of stresses in cylinder head (14).

 Installation: Replace cylinder head bolts. Lubricate thread and contact surface on the cylinder head bolts.

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01G

24

Remove cylinder head (14)

 Installation: Replace cylinder head gasket and pilot bushing.



Clean

25

Clean sealing surfaces of cylinder head (14) and crankcase

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

26

Clean threaded holes

 Blow dirt or fluid out of the threaded holes.



Check

27

Check sealing surfaces for cylinder head (14) for unevenness, cracks and notches


The sealing surface of the cylinder head (14) must not be machined.
Leaks and damage will occur otherwise.

 Check the sealing surface over the whole length and diagonal.
Commercially available devices/tools
Straightedge
Feeler gage

Permissible flatness deviation across overall length

*BE01.30-N-1001-02T

If the deviation lies outside of tolerance range.



Replace cylinder head (14)

28

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.

AS00.00-Z-0005-01A

29

Check for leak tightness with engine running

 Visual inspection only.

Check values for cylinder head

Number

Designation

Engine 607, 608

BE01.30-N-1001-02T

Permissible flatness deviation across overall length

mm

0,05

 Cylinder head

Number

Designation

Engine 607 in model 415

BA01.30-N-1001-01G

Screw/bolt, cylinder head to crankcase

Stage 1 initial torque

Nm

25

Stage 2

Nm

-

Stage 3

°

270

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09