Remove/install cylinder head

AR01.30-S-5800EA

Remove/install cylinder head

06.03.2020

Engine

654.9 in model 447

1

Cylinder head

2

Vacuum line

3

Slide rail

6

Screw

7

Engine suspension lug

8

Intermediate gear

9

Timing chain

11

Engine suspension lug

1

Cylinder head

12

Cylinder head bolt

13

Cylinder head bolt

14

Cylinder head bolt

15

Cylinder head bolt

16

Cylinder head bolt

17

Cylinder head bolt

18

Cylinder head bolt

19

Cylinder head bolt

20

Cylinder head bolt

21

Cylinder head bolt

22

Cylinder head bolt

23

Cylinder head bolt

24

Cylinder head bolt

25

Cylinder head bolt

26

Cylinder head bolt

1

Cylinder head

4

Bracket

5

Engine suspension lug

7

Engine suspension lug

11

Engine suspension lug

 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

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

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

Remove engine with transmission.

AR01.10-S-2401EA

2

Remove air intake line upstream of exhaust gas turbocharger.

AR09.40-S-0500EA

3

Remove hydraulic valve play compensation elements.

AR05.00-S-2011EA

4

Remove charge-air distributor.

AR09.41-S-8683EA

5

Remove upper slide rail (3).

AR05.10-S-8421EA

6

Remove screw (6).

 Bolt, journal/intermediate gear to cylinder head

*BA05.10-N-1001-02EA

7

Remove intermediate gear (8), remove timing chain (9), and secure against falling down.

8

Remove the alternator

Engine 654.9 in model 447
except code HH4 (THERMOTRONIC automatic climate control)
except code HH9 (Air conditioner, automatic heater control)

AR15.40-S-5032EA

9

Remove coolant feed line.

AR20.20-S-0006EA

10

Remove exhaust manifold.

AR14.10-S-3006EA

11

Remove high-pressure exhaust gas recirculation cooler.

AR14.20-S-7682EA

12

Remove vacuum line (2) from the engine lifting lug (11) and from the crankcase.

 M61

*BA00.10-N-1002-04A

13

Remove fuel return line from the crankcase and from the timing case cover.

 M61

*BA00.10-N-1002-04A

14

Remove the pressure transducer for the front vacuum cell.

AR09.40-S-1014EA

15

Expose engine lifting lug (5).

16

Remove engine lifting lug (11).

 Screw, rear lifting lug to cylinder head

*BA01.30-N-1004-01EA

17

Remove cylinder head bolts (12 to 26) in reverse order.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

 Installation: Lubricate thread and bolt head contact surface of cylinder head bolts (12 to 21) using engine oil.
Tighten cylinder head bolts (12 to 26) in numerical sequence.

 Screw/bolt, cylinder head to crankcase

*BA01.30-N-1001-01EA

 Bolt, cylinder head to timing case cover

*BA01.30-N-1006-01EA

18

Remove cylinder head (1) with the aid of an assistant.

19

Remove cylinder head gasket.

 Installation: Install new cylinder head gasket.

20

Remove holder (4).

If a new cylinder head (1) is installed.

 Bolt, bracket for engine cover on cylinder head

*BA01.30-N-1005-01EA

21

Remove engine lifting lugs (5, 7).

If a new cylinder head (1) is installed.

 Screw, front lifting lug to cylinder head

*BA01.30-N-1003-01EA

 Screw, rear lifting lug to cylinder head

*BA01.30-N-1004-01EA

22

Remove glow plugs.

If a new cylinder head (1) is installed.

AR15.20-S-4111EA



Check

23

Check sealing surfaces on the cylinder head (1) and on the crankcase for cracks and unevenness.

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

If there is a problem,



Replace cylinder head (1) or crankcase.

24

Check the length of the cylinder head bolts (12 to 21).

AR01.30-S-5800-03E

Cylinder head bolt

*BE01.30-N-1001-04A

If there is a problem,



replace the necessary cylinder head bolt (12 to 21).



Clean

25

Clean oil and coolant from threaded holes of cylinder head bolts (12 to 26) in the crankcase using compressed air.

26

Clean the sealing surfaces on the cylinder head (1).

If the cylinder head (1) is reused.

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

Assembly cleaner

*BR00.45-Z-1028-04A

27

Clean sealing surfaces on crankcase.

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

Assembly cleaner

*BR00.45-Z-1028-04A

28

Install in the reverse order.

Check values for cylinder head/cylinder head bolts

Number

Designation

Engine 654 in model 447

BE01.30-N-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

215 (0,5)

Max. length (L)

mm

217

For picture, see

AR01.30-S-5800-03E

 Metric bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-N-1002-04A

M61

Nm

9

13

 Cylinder head

Number

Designation

Engine 654.9 in model 447

BA01.30-N-1001-01EA

Screw/bolt, cylinder head to crankcase

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

°

90

Stage 4

°

90

Stage 5

°

90

Stage 6

°

90

 Cylinder head

Number

Designation

Engine 654.9 in model 447

BA01.30-N-1003-01EA

Screw, front lifting lug to cylinder head

Nm

20

 Cylinder head

Number

Designation

Engine 654.9 in model 447

BA01.30-N-1004-01EA

Screw, rear lifting lug to cylinder head

Nm

29

 Cylinder head

Number

Designation

Engine 654.9 in model 447

BA01.30-N-1005-01EA

Bolt, bracket for engine cover on cylinder head

Nm

20

 Cylinder head

Number

Designation

Engine 654.9 in model 447

BA01.30-N-1006-01EA

Bolt, cylinder head to timing case cover

Nm

20

 Gearwheel drive

Number

Designation

Engine 654.9 in model 447

BA05.10-N-1001-02EA

Bolt, journal/intermediate gear to cylinder head

Nm

57

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01