Remove/install cylinder head

AR01.30-Y-5800A

Remove/install cylinder head

25.10.2019

Engine

400.950 in model 400.204/207/212/216/231

Engine

400.951 in model 400.216/241/243/262/281

Engine

400.954/956 in model 831.247

Cylinder head removal procedure

3

Rocker arm screws

4

Ball pin

99

Exhaust gas manifold

100

Intake manifold

101

Rocker arm spindle assembly

11

Special tool impact extractor 355 589 01 63 00

102

Push rods

103

Intake valve bridges

104

Exhaust valve caps

11

Special tool impact extractor 355 589 01 63 00

12

Injector safety clip bolt

13

Threaded insert 904 589 00 63 00

105

Cylinder head bolts

106

Special tool lifting device 904 589 01 63 00

107

Cylinder head seal

208

Cylinder head assembly

Cylinder head refitment procedure

105

Cylinder head bolts

106

Special tool lifting device 904 589 01 63 00

107

Cylinder head seal

207

Cylinder head dummy

208

Cylinder head assembly

10

High pressure pipes

104

Exhaust valve caps

209

Retaining clamp

97

Over flow valve

101

Rocker arm spindle assembly

102

Push rods

103

Intake valve bridges

93

Rocker cover

95

Unit injection pump

96

O-ring

107

Cylinder head seal

210

Special tool sleeve 904 589 03 14 00

211

Unit pump

212

Unit pump fuel feed line O-ring

 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

 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-0001-01B

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Remove

1

Remove exhaust manifold (99) from cylinder head.

AR14.10-Y-3915-01A

2

Remove intake manifold (100) with seal by removing the mounting bolts from cylinder head.

 Loosen all rocker arm screws (3) of the ball pin (4).

3

Remove rocker arm spindle assembly (101) by removing the mounting bracket bolts from cylinder head.

4

Remove all push rods (102) from cylinder head.

5

Remove all intake valve bridges (103) from intake valve.

6

Remove all exhaust valve caps (104).


Mark the pressure pipe according to cylinder.
This is required for assembly purpose.

 Loosen the pressure pipe screw plugs and remove the pressure pipe using special tool impact extractor (11) from cylinder head.

 Impact extractor

*355589016300

7

Remove injector safety clip bolts (12).

8

Install special tool impact extractor (11) and thread insert (13) to the injector and remove injector from the cylinder head.


The injector at the nozzle tip area and fuel intake port must be covered with polyethylene wraps.
Covering is required to avoid dust and damages.

 Mark injectors according to their respective cylinder after removing from cylinder head.

 Threaded insert

*904589006300

 Impact extractor

*355589016300

9

Remove cylinder head bolts (105).

 Loosen cylinder head bolts from the outer towards the center of the cylinder head based on the sequence below.

10

Remove cylinder head from crankcase using crane.

 Install special tool lifting device (106) on the cylinder head (208).

 Lifting device

*904589016300

11

Remove cylinder head gasket (107) from the crankcase.



Measure

12

Measure cylinder head bolt shank length.

AR01.30-Y-5800-03A

13

Check cylinder head and crankcase flatness.

AR01.40-Y-9133-01A

14

Measure the cylinder head height.

AR01.30-Y-5800-12A



Install

15

Install cylinder head dummy (207) plug to the cylinder head assembly.

 Apply sealant.

Loctite sealant 648

*BR00.45-Z-1097-01A

 Cylinder head dummy plug (Sealant in drops)

*BF18.00-Y-1005-01A

16

Install new cylinder head gasket (107) over the crankcase.

 ‘TOP’ mark on the cylinder head gasket must face the cylinder head while installing. Locate seal in the dowel pins.

17

Lift and install cylinder head assembly (208) on the crankcase, using special tool lifting device (106) with the help of jib crane.

 Tighten cylinder head bolts (105).

 Cylinder head bolts

*BA01.10-Y-1202-02B

 Lifting device

*904589016300

18

Strictly follow the cylinder head bolts tightening sequence.

 Failure to comply may result in cylinder head cracks.

19

Install injectors with new O-ring on the cylinder head.



BB00.40-P-0267-01A

 Apply recommended lubricating grease on O-ring before installation.

20

Install high pressure pipes (10) to the cylinder head and tighten the screw plugs.

 Pressure pipes to the cylinder head

*BA01.10-Y-1147-02B

21

Install injectors with safety clip (209) on cylinder head.

22

Install injector safety clip bolts and tighten.

 Injector retainer clamp bolts

*BA01.10-Y-1148-02B

23

Install caps (104) over exhaust valves.

24

Install intake valve bridges (103) over intake valves.

 Ensure milled recess arrow on the valve bridge faces on the unit pump side/ push rod side.

25

Install push rods (102) into the cylinder head and align it over the tappets.

 Ensure proper seating of push rods over the tappets. This can also be checked by viewing it from unit pump holes during assembly.

26

Install rocker arm assembly (101) over cylinder head, and tighten the mounting bolts.

 Rocker arm assembly over cylinder head

*BA01.10-Y-1149-02B

27

Adjust valve clearance.

AR05.30-Y-4202-01A

28

Install over flow valve (97) to cylinder head.

29

Install special tool sleeve (210) on unit pump (211) and insert the upper O-ring (96) over sleeve in upper groove. Slide back the sleeve and insert the lower O-ring on the lower groove. Finally, install unit pump fuel feed line O-ring (212).

 Upper O-ring in black color and lower O-ring in green color.

 Sleeve

*904589031400

30

Install unit injection pumps (95) on crankcase by tightening the bolts to crankcase. Rotate the flywheel using special tool turning device to install remaining unit pumps.

 Unit pumps without load can be identified when it seats completely in the crankcase and can be bolted easily.
Unit injection pump has to be fitted to its respective cylinders (for e.g. 1st cylinder unit pump to 1st cylinder).

 Turning device

*904589046300

31

Install intake manifold with new seal (107) over the cylinder head and tighten the bolts.

 Care must be taken in fitting the intake manifold gasket; such that the ‘TOP’ mark faces upward.

 Intake manifold with new gaskets over the cylinder head

*BA01.10-Y-1151-02B

32

Install rocker cover (93) with seal on the cylinder head by tightening the screws with new O-ring on the cylinder head.

 Rocker cover seal and screw O-rings needs to be replaced once to be removed.

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1147-02B

Pressure pipes to the cylinder head

Nm

40

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1148-02B

Injector retainer clamp bolts

Nm

305

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1149-02B

Rocker arm assembly over cylinder head

Nm

30

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1151-02B

Intake manifold with new gaskets over the cylinder head

Nm

25

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1202-02B

Cylinder head bolts

Stage 1

Nm

70

Stage 2

Nm

170

Stage 3

Nm

280

Stage 4

°

90

Stage 5

°

90

 Filling capacity-(Engine-OM-906 LA)

Number

Designation

Engine 400.950 in model 400.204/207/212/216/231
Engine 400.951 in model 400.216/241/243/262/281
Engine 400.954/956 in model 831.247

BF18.00-Y-1005-01A

Cylinder head dummy plug (Sealant in drops)

Black colour 3-3.5 mm thickness

ml

6

Repair materials

Number

Designation

Order number

BR00.45-Z-1097-01A

Loctite sealant 648

A 003 989 32 71 00 10