Remove/install cylinder head

AR01.30-B-5800TA

Remove/install cylinder head

10.01.2020

Engine

904.91/92/95/96/97 in model 688.2, 958.0

Engine

904.92/93/97/98 in model 693.0/1, 694

Engine

904.92/94/95/96/97/98 in model 368.00/1, 382.11, 384.2, 688.2

Represented in engine 904.9

1

Acoustic encapsulation

2

Supercharged air collector

3

Injection pipe

4

Rocker mechanism

5

Valve bridge

6

Tappet rod

7

Sealing gasket

8

Connecting piece

9

Screws

10

Joining sleeve

11

Engine harness

12

Coolant line

B65

Coolant temperature sensor

Represented in engine 904.9

13

Exhaust manifold with turbocharger

14

Top Brake piping

15

Compressor cooling pipe

16

(Overflow) fuel line

17

Cylindrical head bolt

18

Engine head

19

Cylinder head gasket

20

Centering sleeve

14

Top Brake pipes

19

Cylinder head gasket

22

Precision ruler

17

Cylindrical head bolt

20

Centering sleeve

23

Shifting lever with support (only vehicles with code (GS1) "mechanical" shifting)

18

Engine head

21

Lifting device

L

Thread length

Only on engine 906.9 with code (GS3) "hydraulic" gear shifting

30

Hydraulic piping

31

Clamps

32

Support

33

Screws

 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

 

Remove/install

1

Turn off ignition

 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

2

Disconnect battery ground cable

Topical note

Notes on battery

AH54.10-P-0001-01A

3

Open the maintenance cover

 Warning

Risk of injury caused by body parts being pinched or crushed 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 it with the safety strut.

AS60.80-Z-0001-01A

4

Tilt the cabin

Topical note

Notes on tilting the cab

.

AH60.80-N-0003-01A

 Installation: return the cab to its original position only after the tightness test is performed.

 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

5

Drain the coolant

Drain/pour in coolant
.

AR20.00-B-1142TC

6

Remove the acoustic encapsulation (1) at chassis rear part

7.1

Remove the shifter lever with support (23) on the cylinder head (18)

Vehicles with code (GS1), "mechanical" gearbox

7.2

Remove the clamps (31) and the support (32) of the hydraulic piping (30) on the cylinder head (18)

Vehicles with code (GS3), "hydraulic" gearbox

8

Removing the turbocharger (2) intake duct

.

AR09.41-B-8681A

9

Remove the exhaust manifold with the turbocharger (13) from the cylinder head (18)

.

AR14.10-B-3915A

10

Disassembling the pipes of the injectors (3)

.

AR07.15-B-9235TA

11

Remove the Top Brake piping (constant throttle) (14) on the cylinder head (18)

12

Remove the fuel return line (16) on the cylinder head (18)

13

Remove the air compressor (15) coolant pipe on the cylinder head (18)

14

Separate the engine electric wiring harness (11) on the coolant temperature sensor (B65)

 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

15

Remove the joining piece (8) on the cylinder head (18) and on the coolant pump

Remove/install connection piece of coolant pump to cylinder head
.

AR20.10-B-1290-02TJ

 Installation: replace the connecting piece (10) and sealing (7).

 .Support in the cooling pump

*BA20.10-B-1005-01B

16

Disassembling the rocker arms bracket (4)

Remove/install rocker arm assembly
.

AR05.00-B-5521TC

17

Remove the tappet push rods (6)

 Installation: Observe the correct seating of the tappet push rods (6) on the tappets.

18

Remove the cylinder head bolts (17)

.

AR01.30-B-5800-07TA

 Installation: Follow the tightening specification of the cylinder head (17) bolts.

 .Crankcase bolt

*BA01.30-B-1002-01C

 Socket wrench bit

*422589020900

19

Lift the cylinder head (18) with the lifting device (21) and remove the cylinder head gasket (19)

 To prevent installed injection nozzles damage lay the cylinder head (18) on its side not on its mating surface.

 Installation: install new cylinder head gasket (19) with the writing facing up. Observe for the correct seating of the centering sleeves (20).

 Lifting device

*904589016300

20

Plug all holes in the partitioning surface of the engine block with own-manufacturing plugs



Stop plugs for closing off bores

.

WF58.50-W-0100-04A

Inspect

21

Check the engine block mating surface

.

AR01.40-B-9129TA

 If necessary repair the damaged engine block mating surface.

Maximum admissible deviation of the flatness at the engine block surface

*BE01.40-B-1013-02C

22

Measure the shank length (L) of the cylinder head bolts (17)

 If the maximum length of the rod (L) is exceeded, the corresponding screw of the head (17) should be replaced.

Cylinder head bolts

*BE01.30-B-1001-01H

23

Check the cylinder head mating surface, as well as the cylinder head gasket (19) for cracks and damages

.

AR01.30-B-5800-15TB

.Cylinder head height

*BE01.30-B-1001-02C

Maximum permissible flatness deviation of cylinder head mating surface

*BE01.30-B-1002-02C

If necessary replace or machine the cylinder head (18):



Check/face-grind cylinder head contact surfaces
.

AR01.30-B-7162TA

24

Install in reverse order

 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

25

Start the engine and leave at idle for about 10 seconds until the oil pressure is created, let the engine run at alternating speed

26

Stop the engine and check the area of the cylinder head (18) for tightness

 Visual inspection.

27

Check the engine oil level with the dipstick or on the display; fill up if necessary



Notes on engine oil

.

AH18.00-B-0101-01A

 Observe the quality of the engine oil in the maintenance system or in the guideline of auxiliary materials.

28

Synchronize the starting time of the checking page

 Only on vehicles with MTCO tachograph.

Cylinder head bolt test values

Number

Designation

Engine 902.9; 904.9; 906.9; 924.9; 926.9

BE01.30-B-1001-01H

Cylinder head bolts

thread diameter

mm

16x2

length (L), new bolt

mm

148,5...149

length (L), max. used bolt

mm

151

Test values for the head

Number

Designation

Engine 904.9/906.9

BE01.30-B-1001-02C

Cylinder head height

standard

mm

107,9...108,1

minimum after machining

mm

106,9

Test values for the head

Number

Designation

Engine 904.9/906.9

BE01.30-B-1002-02C

Maximum permissible flatness deviation of cylinder head mating surface

on overall length

mm

0,05

over a length of 150mm

mm

0,02

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1013-02C

Maximum admissible deviation of the flatness at the engine block surface

On the total length

mm

0,030

on a 150 mm length

mm

0,015

 Cylinder head

Number

Designation

Engine 904.9, 906.9

BA01.30-B-1002-01C

Crankcase bolt

1st stage

Nm

20

2nd stage

Nm

70

3rd stage

Nm

170

4th stage

Nm

280

5th stage

Graus

90

6th stage

Graus

90

 Coolant pump, thermostat

Number

Designation

Engine 904.9, 906.9

BA20.10-B-1005-01B

Support in the cooling pump

Nm

50