Remove/install cylinder head

AR01.30-T-5800A

Remove/install cylinder head

10.11.11



Removing

1

Open left rear maintenance flap

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

2

Drain coolant

 See Operator's manual



Notes on coolant

All engines

AH20.00-N-2080-01A

3

Remove screw/bolts attaching intake manifold



- Separate cable tie for attaching wiring harness at intake manifold.

- Unbolt intake manifold from connecting piece (with flame starting system).

- Unbolt intake manifold from cylinder head.

For this step, take off clamps attaching fuel line of flame starting system and separate and seal its connections.

- Remove intake manifold from sealing surfaces to cylinder head and take out gaskets.

4

Remove coolant pipe between coolant pump and oil-water heat exchanger

 Only if automatic transmission fitted.

AR20.20-T-7450-02A



*BA20.10-N-1006-01H

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

5

Remove exhaust manifold



- Slacken screw/bolts of exhaust manifold /turbocharger connecting piece and unscrew

- Slacken screw/bolts of exhaust manifold /cylinder head and unscrew

- Take off two-part exhaust manifold.

- In doing so remove both gaskets and seals (8) between the cylinder head exhaust manifold,

- the connection piece and both sealing rings between the exhaust manifolds, as well as

- the seal to the turbocharger connection piece

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

6

Detach injection lines

AR07.11-T-9230A

7

Detach leak oil line from nozzle holder

8

Take off cylinder head cover (3)

 Take off gasket (4) at cylinder head.

9

Remove rocker arm bracket (13)

10

Pull push rods (5) out of crankcase

11

Slacken cylinder head bolts (10, 11, 12) and unscrew

 The cylinder head bolt below the nozzle holder can be slackened only with the special wrench. It cannot be removed from the cylinder head.



*403589020300

12

Take off cylinder head (7)

AR01.30-T-5800-11A



*403589020300

13

Clean all parts and inspect for wear

 In particular, thoroughly clean

- threaded holes in crankcase,

- cylinder head separating surface, and

- face of crankcase.

- Remove remaining water.



Checking

14

Inspect crankcase contact surface for damage and corrosion points

 If present, face-grind the crankcase contact surface.

15

Inspect flatness of crankcase contact surface

Inspect flatness of crankcase contact surface with knife-edge straightedge over entire length and diagonally.

If a light gap is formed:

Inspect permissible variation with feeler gage.

 It must not be possible to push feeler gage between crankcase contact surface and straightedge.
If checked in transverse direction, the specified permissible variation is merely a reference value and cannot be measured.

Crankcase - flatness of contact surface

*BE01.40-N-1006-02F

Peak-to-valley height (Rz) of crankcase

*BE01.40-N-1005-02F

Straightedge

Steel rule

 If present, face-grind the crankcase contact surface.

16

Check flatness of cylinder head

AR01.30-T-5800-12A

*BE01.30-N-1001-02H

Straightedge

Steel rule



Install

17

Fit cylinder head (7) onto crankcase

AR01.30-T-5800-11A

18

Tighten cylinder head bolts (10, 11, 12) as specified in tightening pattern

- Lightly oil cylinder head bolts.

- Observe tightening procedure: 

Tightening specifications for cylinder head bolts

AR01.30-T-5800-07A

- Mark socket set (15).

 For screw/bolt below nozzle holder use  box wrench bit.

Cylinder head bolts

*BE01.30-N-1001-01E



*BA01.30-N-1001-01H



*000589620901



*403589020300

19

Insert tappet rods (5)

20

Fit on rocker arm bracket (13) and tighten screw/bolts (14) slightly

 Align rocker arms to valves.

21

Tighten screw/bolts (14) of rocker arm bracket (13) fully



*BA05.00-N-1001-01E



*000589642100

22

Set valve clearance

 See Maintenance Manual.

23

Fit on cylinder head cover (3) and tighten screw/bolts (1) fully

 Replace gasket.



*BA01.20-N-1001-01F

24

Connect up injection lines

AR07.11-T-9230A

25

Plug in leak oil lines onto nozzle holders

26

Install intake manifold



- Fit on seals, insert intake manifold.

- Attach intake manifold to cylinder head.

- Screw/bolt, intake manifold to connecting piece (with flame starting system).

- Attach wiring harness with cable tie to intake manifold.

 Screw/bolt, intake manifold to cylinder head

*BA09.20-N-1001-02G

27

Install fuel line of flame starting system

28

screw/bolt bracket onto intake manifold

 For this step, also attach clamp for securing fuel feed line of flame starting system.

29

Install exhaust manifold



- Replace seal (8),

- sealing rings between both exhaust manifolds, as well as

- exhaust manifold seal/ turbocharger connection piece

.

- Tighten screw/bolts for exhaust manifold

- beginning in each case in the middle to the outside diagonally across,

- at first screw in until they make contact and then tighten slightly, and finally

- tighten to the

specified torque.



*BA14.10-N-1004-01E



*BA09.40-N-1001-01E

30

Remove coolant pipe between coolant pump and oil-water heat exchanger

 Only if automatic transmission fitted.

AR20.20-T-7450-02A

31

Pour in coolant



*BF20.00-N-1001-01D

32

Close engine compartment flap at rear left

33

Bleed fuel system

 See Maintenance Manual.

Number

Designation

Engine 447

Engine 489

BE01.30-N-1001-01E

Cylinder head bolt
M15X2

Shank length

mm

109.0

109.0

Shank length

mm

144.0

144
.0

Shank length

mm

168.0

168.0

Number

Designation

Engine 447

Engine 489

BE01.30-N-1001-02H

Cylinder head

Overall height

mm

113.9-114

113.9-114

Minimum height

mm

113.3

113.3

permissible unevenness of lower contact surface over a length
of 150 mm

mm

0.015

0.015

permissible deviation of upper to lower contact surface

mm

0.2

0.2

protrusion of injection nozzles in cylinder head

mm

1.6-2.4

1.6-2.4

Number

Designation

Engine 447

Engine 489

BE01.40-N-1005-02F

Peak-to-valley height (Rz) of crankcase

Upper contact surface

μm

0 - 0.016

0 - 0.016

Lower contact surface

μm

0 - 0.016

0 - 0.016

BE01.40-N-1006-02F

Crankcase - flatness of contact surface

Over entire length

mm

0.030

0.030

Over a length of 150 mm in longitudinal and transverse direction

mm

0.015

0.015

Number

Designation

Engine 447

Engine 489

BA01.20-N-1001-01F

Screw/bolt, cylinder head cover to cylinder head

Nm

25

25

Number

Designation

Engine 447

Engine 489

BA01.30-N-1001-01H

Cylinder head bolt to crankcase

Stage 1

Nm

10

10

Stage 2

Nm

50

50

Stage 3

Nm

100

100

Stage 4

Nm

140

140

Stage 5

Nm

180

180

Stage 6

°

95

95

See picture

-

-

Number

Designation

Engine 447

Engine 489

BA05.00-N-1001-01E

Screw/bolt, rocker arm bracket to cylinder head

Nm

75

75

Number

Designation

Engines 447, 489

BA09.20-N-1001-02G

Screw/bolt, intake manifold to cylinder head

Nm

25

Number

Designation

Engines 447, 489

BA09.40-N-1001-01E

Nut, turbocharger to exhaust manifold

Nm

50

Number

Designation

Engines 447, 489

BA14.10-N-1004-01E

Screw/bolt, exhaust manifold to cylinder head

Nm

50

Number

Designation

Engines 447, 489

BA20.10-N-1006-01H

Screw/bolt, coolant pipe to coolant pump

Nm

25

Number

Designation

Engine 447

Engine 489

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

76 to 92

70 to 80

with VOITH retarder

Liters

-

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

BB00.40-P-0325-02A