Remove/install cylinder head

AR01.30-D-5800NB

Remove/install cylinder head

14.2.12

 

Remove/Install

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 contact with fuel.

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

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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

1

Disconnect battery ground cable



Notes on battery

AH54.10-P-0001-01A

2

Remove heat shield above turbocharger

3

Remove cylinder head cover

AR01.20-D-5014NB

4

Drain coolant

 Installation: Before filling the cooling system check for leaktightness.

AR20.00-D-1140NA

5

Disconnect engine wiring harness at generator and turbocharger (12), guide out to the top along the engine and place to the side

 Installation: Ensure correct routing of engine wiring harness.



*BA15.40-P-1002-01D



*BA15.40-P-1003-01D

6

Detach fuel lines (6, 7) at the support (3)

7

Detach brackets of fuel lines (6, 7) at charge air distribution tube (2)

8

Detach support (3) at charge air distribution tube (2) and only slacken at crankcase



*BA09.41-N-1002-01F



*BA09.41-N-1003-01F

9

Detach fuel hose (4) at fuel line (5)

 Collect escaping fuel.

10

Remove camshafts

AR05.20-D-6992NB

11

Remove the camshaft housing (18) from cylinder head (1)

 Installation: At the time of fitting, pay attention to the fitted sleeves (17) for locating the camshaft housing (18).

12

Remove intermediate gear of high pressure pump (9)

AR05.10-D-4650NB

13

Detach oil feed line (13) at turbocharger (12) and at cylinder head (1)

 Replace sealing ring (14).



*BA09.40-P-1004-01C



*BA09.40-P-1005-01C

14

Slacken support at turbocharger (12) and at crankcase

 Only slacken bolts, in order to mount the turbocharger (12) free of tension.



*BA09.40-P-1006-01C



*BA09.40-P-1007-01C

15

Detach noise insulation (19) at the turbocharger (12)

 Installation: Install new sealing ring (20).

16

Detach exhaust clamp (21) at turbocharger (12)

17

Detach the turbocharger (12) at the exhaust manifold (23)

 Installation: Replace gasket between turbocharger (12) and exhaust manifold (23).



*BA09.40-P-1001-01C

18

Detach oil dipstick guide tube for automatic transmission (15) at cylinder head (1)

19

Detach coolant pipe (16) at cylinder head (1) and place to the side with connected coolant hoses

20

Detach the charge air hose (8) at the charge air manifold (2)

 Pull up clamp at charge air distribution tube (2).

21

Detach the coolant hose (25) at the exhaust gas recirculation positioner (24)

22

Unplug plug at exhaust gas recirculation positioner (24)

23

Detach coolant hoses (26, 27) at the coolant thermostat housing

 Check condition of coolant hoses (26, 27) and hose clamps, replace if necessary.

24

Unscrew bolts (28), and loosen and unscrew the cylinder head bolts (29) in stages

 Slacken cylinder head bolts (29) in the reverse order of the tightening pattern once engine has cooled down.

 Installation: Observe tightening pattern of bolts (28) and of cylinder head bolts (29). Oil thread and head contact surface of cylinder head bolts (29) and insert. Bolts (28) and cylinder head bolts (29) need not be tightened again.

AR01.30-P-5800-01TB



*BA01.30-P-1001-01I



*BA01.30-P-1002-01I

25

Check cylinder head bolts (29), replace if necessary

AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

26

Take cylinder (1) off the crankcase

 Installation: Fit new cylinder head gasket (30) onto the crankcase and fix with fitted sleeves (31).

When fitting on the cylinder head (1) observe fitted sleeves (31) for locating.

27

Clean cylinder head separating surfaces and tapped holes

 Blow out tapped holes free of oil and water.

28

Check cylinder head separating surface

 Face-grind cylinder head separating surface if necessary

29

Install in the reverse order

30

Inspect ATF level of automatic transmission



Automatic transmission - oil and filter change

AP27.00-D-2702C

 Danger!

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

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 caused by ignition or explosion of fuel. 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

31

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

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

32

Encode radio, set clock

Number

Designation

Engine
647.981

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

max. length (L)

mm

104

For picture, see

AR01.30-P-5800-03HB

Number

Designation

Engine
647.981

BA01.30-P-1001-01I

Bolt of cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1002-01I

Bolt, cylinder head to crankcaseM12

1st stage

Nm

15

2nd stage

Nm

60

Step 3

°

90

4th stage

°

90

Number

Designation

Engine
647.981

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 socket

Nm

20

Banjo bolt

Nm

18

BA09.40-P-1005-01C

Bolt of oil feed line to cylinder head

Nm

9

BA09.40-P-1006-01C

Bolt of support to turbocharger

Nm

30

BA09.40-P-1007-01C

Bolt of turbocharger support to crankcase

Nm

20

Number

Designation

Engine 647.981

BA09.41-N-1002-01F

Bolt of support to charge air distribution pipe

Nm

14

BA09.41-N-1003-01F

Bolt of support of charge air distribution pipe to crankcase

Nm

20

Number

Designation

Engine
647.981

BA15.40-P-1002-01D

Nut of circuit B+ to generator

Nm

18

BA15.40-P-1003-01D

Nut of circuit D+ to generator

Nm

5