Remove/install right cylinder head

AR01.30-S-5780PS

Remove/install right cylinder head

18.02.2020

Engine

642 in model 470, 471

1

Cylinder head

11

Cylinder head seal

13

Cylinder head bolt

14

Cylinder head bolt

15

Crankcase

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Disconnect ground line from battery.

AR54.10-S-0003P

2

Remove hood.

AR88.40-S-3000P

3

Drain off coolant.

AR20.00-S-1142PS

 Installation: Install front engine compartment lining only after the leak test.

4

Drain engine oil.



AP18.00-S-0101PS

 Installation: Install center engine compartment lining only after the leak test.

5

Remove charge-air distributor.

AR09.41-S-8683PS

 Installation: Install top engine compartment lining only after the leak test.

6

Remove heat shield from right exhaust manifold.

AR14.10-S-3008PS

7

Remove right camshaft sprocket.

AR05.20-S-6040PS

8

Remove right camshafts.

AR05.20-S-6992PS

9

Pull slide rail pin out of the cylinder head (1).

AR01.30-S-5800-04PS

 Installation: Screw suitable screw into slide rail pin, drive slide rail pin into the cylinder head (1), and remove screw again.

 Puller

*605589003300

 Threaded bolt

*116589013400

 Impact extractor

*116589203300

10

Loosen cylinder head bolts (13, 14) in stages in reverse order of the tightening procedure and remove.

Tightening procedure

AR01.30-S-5800-01SE

Topical note

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

AH00.00-P-0020-01A


Observe loosening and tightening procedure.
Otherwise, damage to the cylinder head (1) will occur.

 Screw/bolt, cylinder head to crankcaseM12

*BA01.30-N-1003-01PS

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1004-01PS

11

Remove cylinder head (1).

12

Remove cylinder head gasket (11).

 Installation: Replace cylinder head gasket (11).

13

Cover threaded holes and sealing surfaces on the crankcase (15).

14

Remove glow plugs.

If a new cylinder head (1) is installed.

AR15.20-S-4111PS

15

Remove valves.

If a new cylinder head (1) is installed.

AR05.30-S-3511SE

16

Remove exhaust manifold.

If a new cylinder head (1) is installed.

AR14.10-S-3008PS



Check

17

Check cylinder head bolts (13) for elongation.

AR01.30-S-5800-03SE

Cylinder head bolt

*BE01.30-N-1001-04A

18

Check cylinder head (1) for cracks and unevenness.

If a new cylinder head (1) is not installed.


The cylinder head (1) must not be reworked (surface grinding).
Otherwise, the cylinder head (1) will be damaged.

If cracks or unevenness can be detected,



Replace cylinder head(1).

19

Check crankcase (15) for cracks and unevenness.


The crankcase (15) must not be reworked (surface grinding).
Otherwise, the crankcase (15) will be damaged.

If cracks or unevenness can be detected,



replace crankcase (15).



Clean

20

Clean threaded holes and sealing surfaces on the cylinder head (1).

If a new cylinder head (1) is not installed.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

21

Clean threaded holes and sealing surfaces on the crankcase (15).

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

22

Install in the reverse order



Check

 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

23

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

24

Read out fault memory.



AD00.00-S-2000-06P

If there are faults present in the fault memory:



Erase corresponding faults.

Check values for cylinder head/cylinder head bolts

Number

Designation

Engine 642 in model 470, 471

BE01.30-N-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

205

Max. length (L)

mm

207

For picture, see

AR01.30-S-5800-03SE

 Cylinder head

Number

Designation

Engine 642 in model 470, 471

BA01.30-N-1003-01PS

Screw/bolt, cylinder head to crankcaseM12

Stage 1

Nm

10

Stage 2

Nm

60

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

 Cylinder head

Number

Designation

Engine 642 in model 470, 471

BA01.30-N-1004-01PS

Screw/bolt, cylinder head to crankcase

M8x35

Nm

20

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