Remove/install cylinder head

AR01.30-D-5800NA

Remove/install cylinder head

14.2.12

29.6.01

Figure modified from 25 Nm to 18 (2) Nm

Value in BA09.40-P-1004-01C for Engine 612.981 modified

*BA09.40-P-1004-01C

 

Remove/install

1

Remove engine

AR01.10-D-2400NA

2

Detach transmission at engine

*BA27.10-N-1003-04B

3

Mount engine onto assembly stand

4

Remove camshafts

AR05.20-D-6992NA

5

Take out hydraulic valve clearance compensation elements (23)

 Installation: Hydraulic valve clearance compensating elements (23) must be reinserted at the same point where they were removed.

6

Remove camshaft housing (1) from cylinder head (24)

 Installation: When fitting on, observe fitted sleeves (2) for locating the camshaft housing (1).

7

Remove high pressure pump intermediate gear (13)



*BA05.10-P-1005-01A

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

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

AS54.10-Z-0001-01A

8

Disconnect engine wiring harness at engine side

AR15.18-D-1000-01NA



Notes on battery

AH54.10-P-0001-01A

9

Take off charge air distribution tube at cylinder head (24).

AR09.41-D-1310NA

10

Detach oil feed line (19) at cylinder head (24) and at turbocharger (18)

 Replace compression ring (20).



*BA09.40-P-1004-01C



*BA09.40-P-1005-01C

11

Detach turbocharger (18) at exhaust manifold (16)



*BA09.40-P-1001-01C

12

Detach oil dipstick guide tube (5) for automatic transmission at cylinder head (24)

13

Detach coolant pipe (21) at cylinder head (24) and push to the side with connected coolant hoses

14

Detach coolant hoses (9, 11) at coolant thermostat housing

Check condition of coolant hoses (9, 11) and hose clamps (10, 12), replace if necessary.

15

Detach fuel line (3) at rear at rail and unclip at front at fixture

 Handle securing clip carefully.

AR47.25-P-1000-01A

Collect escaping fuel.

Replace compression ring (4).

16

Unscrew bolts (26) and slacken cylinder head bolts (25) in stages and unscrew

 Slacken cylinder head bolts (25) in the reverse order of the tightening pattern once engine has cooled down.

 Installation: Observe tightening pattern of bolts (26) and of cylinder head bolts (25), otherwise damage at the cylinder head (24) could occur. Oil cylinder head bolts (25) at thread and bolt head contact surface and insert. It is not necessary to retighten bolts (26) and cylinder head bolts (25).

AR01.30-P-5800-01HC



*BA01.30-P-1001-01M



*BA01.30-P-1003-01M

17

Inspect cylinder head bolts (25), replace if necessary

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

18

Take cylinder head (24) off the crankcase

 Installation: Lock new cylinder head gasket (27) into the fitted sleeves (28), otherwise it can be damaged during assembly of the cylinder head (24).

 Installation: When fitting on the cylinder head (24), observe fitted sleeves (28) for locating.

19

Clean contact surfaces and threaded holes

 Blow out tapped holes free of oil and water.

Check separating surface of cylinder head (24).

20

Install in the reverse order

21

Bleed low pressure fuel circuit

AR07.16-D-0100A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near engine

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel jets or leakage.

Keep all ignition sources out of hazard area.

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

AS07.16-Z-0001-01A

22

Check oil leakage of vehicle and check for leaks in the fuel system

 Run engine until warm, switch off and inspect for leaks.

23

Inspect cooling system for leaks

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-D-1010C

24

Encode radio, set clock

Number

Designation

Engine 612.981

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

max. length (L)

mm

104

See picture in

AR01.30-P-5800-03HB

Number

Designation

Engine
612.961/962/ 963/965966/967// 981

BA01.30-P-1001-01M

Bolt connecting cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1003-01M

Bolt connecting cylinder head to crankcase M12

Stage 1

Nm

60

Stage 2

Nm

-

Stage 2

°

90

Stage 3

°

90

Stage 4

°

-

Stage 5

°

-

Number

Designation

Engine 612.981/
990

BA05.10-P-1005-01A

Bolt connecting intermediate gear of high pressure pump to cylinder head

Nm

40

Number

Designation

Engine 612.981

BA09.40-P-1001-01C

Flange connection of exhaust manifold to turbocharger

Nm

30

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw fitting

Nm

30

Banjo bolt

Nm

18 (2)

BA09.40-P-1005-01C

Bolt connecting oil feed line to cylinder head

Nm

9

Number

Designation

Trans-mission
722.681

BA27.10-N-1003-04B

Bolt connecting transmission housing to engine

M10

Nm

38