Remove/install cylinder head

AR01.30-D-5800TSC

Remove/install cylinder head

18.02.2020

Engine

274 in model 907

2

Vacuum hose

3

Support brace

4

Nut

5

Nut

9

Screw

1

Cylinder head

6

Cap

7

Slide rail pins

8

Bolts

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

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

AS00.00-Z-0002-01A

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Clamp off ground line of on-board electrical system battery (G1).

AR54.10-D-0029TS

2

Drain off coolant.

AR20.00-D-1142TSC

3

Remove cylinder head cover.

AR01.20-D-5014TSC

4

Remove hydraulic valve play compensation elements.

AR05.00-S-2013EG

5

Remove the catalytic converter.

AR49.20-D-0100TSC

6

Remove charge-air distributor from cylinder head (1).

AR09.41-D-8683TSC

 Charge-air distributor is not fully removed.

7

Remove air intake pipe.

AR09.10-D-8131TSC

 Remove air intake pipe from ATL and place to one side.

8

Remove vacuum hose (2).

9

Unscrew nut (5).

 Nut, heat shield to turbocharger support brace

*BA09.40-N-1014-02F

10

Unscrew nut (4).

 Nut, turbocharger support brace to turbocharger

*BA09.40-N-1012-02F

11

Unscrew screw (9) and remove support (3).

 Bolt, turbocharger support brace to crankcase

*BA09.40-N-1011-02F

12

Remove oil return feed line of the exhaust gas turbocharger.

AR09.40-D-6021TSC

13

Remove oil feed line of exhaust gas turbocharger.

AR09.40-D-6035TSC

14

Remove coolant lines of exhaust gas turbocharger.

AR09.40-D-6020-18TSC

 Screw/bolt, coolant line to exhaust gas turbocharger

*BA09.40-N-1008-02F

 Screw/bolt, coolant line to coolant pump

*BA09.40-N-1009-02F

 Screw/bolt, coolant line to cylinder head

*BA09.40-N-1010-02F

15

Remove both caps (6) at cylinder head (1).

16

Remove both slide rail bolts (7).



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

 Installation: Wet slide rail bolts (7) with oil.

 Puller

*605589003300

 Spindle

*270589003302

17

Remove bolts (8) at connection fitting of coolant thermostat.

 Screw/bolt, coolant thermostat to cylinder head

*BA20.10-N-1005-01CA

18

Unscrew cylinder head bolts in reverse order to tightening procedure.

AR01.30-S-5800-01EG

 Installation: Replace cylinder head bolts.
Pay attention to tightening procedure of the cylinder head bolts.

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01X

 Bolt, cylinder head to timing case cover

*BA01.30-N-1002-01X

19

Remove cylinder head (1).

 Aid of helper required.

20

Transfer exhaust gas turbocharger with exhaust manifold.

When replacing the cylinder head (1).

AR09.40-D-6036TSC

21

Transfer coolant temperature sensor (B11/21).

When replacing the cylinder head (1).

AR15.60-D-2715TSC

22

Modify valves.

When replacing the cylinder head (1).

AR05.30-S-3511EG



Clean

23

Clean sealing surfaces of cylinder head (1) and crankcase.

AR01.00-P-0050-01A

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE


Do not use sharp-edged tools. Sealing surfaces on cylinder head (1) and crankcase must not be reworked.
Leaks and damage nay occur otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

24

Clean threaded holes of cylinder head bolts in crankcase with compressed air.

25

Install in the reverse order



Check

26

Check engine oil level, correct if necessary.



AP18.00-D-0101TSC

 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

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

27

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Cylinder head

Number

Designation

Engine 274 in model 907

BA01.30-N-1001-01X

Screw/bolt, cylinder head to crankcase

Stage 1

Nm

10

Stage 2

Nm

40

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

 Cylinder head

Number

Designation

Engine 274 in model 907

BA01.30-N-1002-01X

Bolt, cylinder head to timing case cover

Nm

20

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1008-02F

Screw/bolt, coolant line to exhaust gas turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1009-02F

Screw/bolt, coolant line to coolant pump

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1010-02F

Screw/bolt, coolant line to cylinder head

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1011-02F

Bolt, turbocharger support brace to crankcase

Stage 1

Nm

15

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1012-02F

Nut, turbocharger support brace to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1014-02F

Nut, heat shield to turbocharger support brace

Nm

10

 Coolant pump, coolant thermostat

Number

Designation

Engine 274 in model 907

BA20.10-N-1005-01CA

Screw/bolt, coolant thermostat to cylinder head

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09