Remove/install cylinder head

AR01.30-S-5800E

Remove/install cylinder head

18.02.2020

Model

447 with engine 651

Modification notes

10.12.2018

Workshop equipment 000 588 00 31 02 Adaption replaced by 000 588 08 31 00 Adapter pick-up fork.

Operation step 1

1

Cylinder head

5

Bracket

9

Lifting eye

2

Exhaust pipe

6

Screw

10

Fuel line

3

Exhaust gas recirculation line

7

Screw

19

Insulation mat

4

Fuel filter

8

Screw

20

Screw

11

Heat shield

12

Screw

13

Screw

16

Lifting eye

18

Hose

14

Screw

17

Screw

N14/8

Glow output stage

15

Screw

1

Cylinder head

22

Screw

21

Screw

23

Cylinder head bolt

 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

 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 contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 

Remove/install

1

Remove engine and install on assembly stand

AR01.10-S-2401E



000 588 00 31 00 Assembly stand for cars

WS01.00-N-3028B



000 588 08 31 00 Mounting fork adapter

WS01.00-P-0186B

2.1

Remove diesel particulate filter

Model 447.### 1# with engine 651
except code MF4 (Emissions category Euro 4 N1 GR.III/N2)
except code ZG2 (Permanent all-wheel drive)

AR14.40-S-1000E

2.2

Remove catalytic converter

Model 447 with engine 651
with code MF4 (Emissions category Euro 4 N1 GR.III/N2)
Model 447.### 1# with engine 651
with code ZG2 (Permanent all-wheel drive)
Model 447.### 2# with engine 651
except code MF4 (Emissions category Euro 4 N1 GR.III/N2)

AR49.10-S-5500EA

3

Remove cylinder head cover

AR01.20-S-5014E

4

Remove vacuum reservoir and place to one side

AR07.09-S-0001E

5

Remove rail

AR07.03-S-1010E

6

Remove guide tube from oil dipstick at cylinder head (1)

AR18.40-S-3510E

7

Remove exhaust pipe (2)

 Bolt, exhaust gas recirculation line to bypass flap

*BA14.20-N-1034-01H

 Bolt, exhaust gas recirculation line to charge air line

*BA14.20-N-1033-01H

8

Remove EGR line (3) on rear cover of cylinder head (1)

 Bolt, exhaust gas recirculation line to rear cylinder head cover

*BA14.20-N-1026-01H

9

Position exhaust gas recirculation cooler with bypass flap

AR14.20-S-7665E

 Do not remove exhaust gas recirculation cooler from bypass flap. It is not necessary to remove the vacuum reservoir.

10

Remove fuel filter (4) with connected fuel lines and place to one side

11

Remove glow plugs

AR15.20-S-4111E

12

Remove bracket (5)

 To do so, remove the screw/bolts (6).

 Screw/bolt, bracket to cylinder head

*BA14.20-N-1028-01H

13

Remove pressure line from high-pressure pump to fuel distributor

AR07.03-S-7000E

14

Remove screws/bolts (7, 8)

15

Push fuel lines away slightly from the lifting eye (9)

16

Remove fuel line (10)

 Seal connections.

 Installation: Replace clamp.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

17

Remove chain tensioner

AR05.10-S-7800E

18

Remove heat shield (11)

 Screw/bolt, heat shield to cylinder head

*BA14.10-N-1008-01O

19

Disconnect flange connection for ATL at exhaust manifold

 To do so, remove screws/bolts (12).

 Flange connection, exhaust manifold to turbocharger

*BA09.40-N-1001-01R

20

Remove screws/bolts (13)

 Screw/bolt, charge air pipe to charge air distributor

*BA09.41-N-1014-01M

21

Remove screw (14)

22

Remove screws (15)

 Bolt, lifting eye/front bracket to cylinder head

*BA01.30-N-1001-01K

23

Place lifting eye (16) with glow output stage (N14/8) to one side

 Do not remove electrical lines.

24

Remove screw (17) of ground line

25

Disconnect electrical connection for the temperature sensor upstream of catalytic converter

AR07.04-S-0004E

26

Remove coolant thermostat

AR20.10-S-2461E

27

Remove camshafts

AR05.20-S-6992E

28

Remove hose (18) from coolant connection fitting

 Hose clamp pliers

*003589033700

29

Remove insulation mat (19) at top at cylinder head (1)

 For this purpose, remove screws (20).

30

Unfasten screw/bolts (21, 22) and slacken cylinder head bolts (23) in stages and unscrew

AR01.30-S-5800-01E


Slacken screw/bolts (21, 22) and cylinder head bolts (23) in reverse order of the tightening procedure once engine has cooled down.
Damage can occur otherwise in the cylinder head (1) due to stresses.

 Installation: Lightly lubricate thread and bolt head contact surface of cylinder head bolts (23).

 Bolt, cylinder head to timing case cover

*BA01.30-N-1003-01K

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1004-01K

 Set of flexible head wrenches

*001589810900

31

Remove cylinder head (1) from crankcase

 Use aid of helper.

 Installation: Apply a sealant bead in the sealing area between the timing case and the crankcase. Fit a new cylinder head gasket on the crankcase. Observe dowel pins for fixing the cylinder head (1) in place. Use aid of helper.



Clean

32

Clean sealing surfaces of cylinder head (1) and crankcase

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can get damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

33

Clean threaded holes of cylinder head bolts (23)

 To do this blow out threaded holes with compressed air and clean away any oil and water.



Check

34

Check sealing surfaces on cylinder head (1) and crankcase for cracks and unevennesses

 The sealing surfaces on the cylinder head (1) and the crankcase must not be reworked.

35

Check cylinder head bolts (23)

AR01.30-S-5800-03E

 Replace cylinder head bolts (23) if necessary.

Cylinder head bolt

*BE01.30-N-1001-04A

36

Install in the reverse order

Check values for cylinder head/cylinder head bolts

Number

Designation

Engine 651 in model 447

BE01.30-N-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

226 (0,5)

Max. length (L)

mm

227,5

For picture, see

AR01.30-S-5800-03E

 Cylinder head

Number

Designation

Engine 651 in model 447

BA01.30-N-1001-01K

Bolt, lifting eye/front bracket to cylinder head

Nm

20

 Cylinder head

Number

Designation

Engine 651 in model 447

BA01.30-N-1003-01K

Bolt, cylinder head to timing case cover

M8

Nm

20

 Cylinder head

Number

Designation

Engine 651 in model 447

BA01.30-N-1004-01K

Screw/bolt, cylinder head to crankcase

M12

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

Stage 6

°

90

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1001-01R

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

20

Stage 2

°

90

 Charge air pipe/charge air cooling

Number

Designation

Engine 651 in model 447

BA09.41-N-1014-01M

Screw/bolt, charge air pipe to charge air distributor

Nm

9

 Exhaust manifold

Number

Designation

Engine 651 in model 447

BA14.10-N-1008-01O

Screw/bolt, heat shield to cylinder head

M6

Nm

9

M8

Nm

20

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 447

BA14.20-N-1026-01H

Bolt, exhaust gas recirculation line to rear cylinder head cover

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 447

BA14.20-N-1028-01H

Screw/bolt, bracket to cylinder head

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 447

BA14.20-N-1033-01H

Bolt, exhaust gas recirculation line to charge air line

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 447

BA14.20-N-1034-01H

Bolt, exhaust gas recirculation line to bypass flap

Nm

10

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