Shown: engine 651.921 in model 205 except code ME04 (Mild-hybrid drive) |
1 | Oil feed lines |
2 | Front holder |
3 | Bolts |
4 | Rear bracket |
5 | Bracket |
6 | Bolts |
7 | Heat shield |
8 | Bracket |
9 | Electrical wiring harness |
10 | Ground cable |
11 | Bracket |
18 | Coolant hose |
22 | Vacuum line |
B5/4 | Low-pressure turbocharger boost pressure sensor |
N14/3 | Glow output stage |
Y31/5 | Boost pressure control pressure transducer |
Y133 | Coolant pump switchover valve |
P01.30-2461-06
P01.30-2460-09
Shown: engine 651.921 in model 205 except code ME04 (Mild-hybrid drive) |
12 | Bracket | 17 | Fuel lines | |
13 | Support brace | 19 | Screw | |
14 | Exhaust gas recirculation line | 20 | Fuel hose | |
15 | Cover | 21 | Coolant hose | |
16 | Bolts | B4/7 | Fuel pressure sensor |
P01.30-2353-09
Shown on engine 651.911 |
24 | Bolts | 29 | Cable tie | |
25 | Screw | 30 | Tensioning rail | |
26 | Bolts | B19/11 | Temperature sensor upstream of turbocharger | |
27 | Bolts | A | Sealed areas | |
28 | Dowel pins |
50 | Marking with "R" stamp |
P01.30-2517-06
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. | |
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. | |
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. | |
Danger | Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure | Keep all ignition sources out of hazard area. | |
Danger | Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | |
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. | |
Danger | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | |
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. | |
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Topical note | General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on coolant | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on battery | ||
Notes about Common-Rail components | |||
| Remove/install | ||
1 | Remove lower engine compartment linings. | ||
| Check | ||
2 | Check coolant for oil fouling. | If the coolant is fouled, | |
| |||
De-oil cooling and heating system. | |||
3 | Drain coolant at radiator. | ||
Installation: | |||
4 | Perform power disconnect of high-voltage on-board electrical system. | Engine 651 in model 205.012/212 | |
5 | Disconnect ground line from battery. | ||
6 | Remove cylinder head cover. | ||
7 | Remove electric line from rail. | Installation: Replace cable tie. | |
8 | Remove engine air intake duct downstream of air filter. | ||
9 | Remove screws and remove oil feed lines (1) at front bracket (2) of air filter housing. | Bolt for oil line bracket | |
10 | Remove screws (3) and remove front bracket (2) of air filter housing. | Screw/bolt, air filter bracket to cylinder head | |
11 | Remove rear bracket (4) of air filter housing from bracket (5) and place to one side with DPF differential pressure sensor | M61 | |
12 | Remove bracket (8) with electrical wiring harness (9) from rear right engine lifting lug and place to one side. | ||
13 | Remove vacuum line (22) of vacuum pump at separating point and place to one side. | The vacuum line (22) runs along the firewall and the connecting point is located in the area of the oil dipstick. | |
14 | Remove screw/bolts (24). | Installation: Replace screws (24) and seal. | |
Flange connection, exhaust manifold to exhaust gas turbocharger | |||
15 | Remove screws (6) and remove heat shield (7) from exhaust manifold | Installation: Ensure heat shield (7) is correctly seated in clips on exhaust manifold. Heat shield (7) is additionally secured with two clips at top and one clip at bottom. | |
Bolt, shield to exhaust manifold | |||
16 | Remove temperature sensor upstream of exhaust gas turbocharger (B19/11) and place to one side with connected electric line. | ||
17 | Remove fuel filter. | ||
| |||
18 | Release and disconnect electrical connectors at glow output stage (N14/3). | ||
19 | Remove screw/bolt for ground line (10) from cylinder head and place ground line (10) to one side. | Engine wiring harness ground connection to cylinder head cover | |
20 | Remove coolant pump switchover valve (Y133) from bracket (11) and place to one side with connected vacuum hoses. | ||
21 | Remove screws of bracket (11) from cylinder head and remove bracket (11). | Lifting eye or bracket for glow output stage to cylinder head | |
22 | Place bracket (11) with glow output stage (N14/3), low-pressure exhaust gas turbocharger boost pressure sensor (B5/4) and boost pressure control pressure transducer (Y31/5) to one side. | ||
23 | Remove the exhaust gas recirculation valve. | ||
24 | Remove the throttle valve actuator. | ||
25 | Remove bracket (12). | Bolt, exhaust gas recirculation line support to cylinder head | |
Bolt, exhaust gas recirculation line support brace to exhaust gas recirculation line | |||
26 | Remove support (13) for exhaust gas recirculation cooler. | Bolt, Y-support brace to cylinder head | |
27 | Remove exhaust gas recirculation line (14) from cover (15). | Installation: Replace seal. | |
Bolt, exhaust gas recirculation line to chain case cover | |||
28 | Remove screw/bolts (16). | ||
29 | Remove fuel lines (17) and seal exposed connections with suitable stop plugs. | Pliers for click clamps | |
30 | Remove the coolant thermostat. | ||
31 | Remove coolant hoses (18, 21) from connection fitting of coolant return line at cylinder head, seal exposed connections with suitable stop plugs and/or protective covers and place to one side | Set of protective covers | |
Record plug | |||
Hose clamp pliers | |||
32 | Remove high-pressure line. | ||
Installation: Install high-pressure line free of tension. | |||
33 | Unscrew screw (19). | Screw/bolt, water outlet to charge air distributor | |
34 | Remove fuel pressure sensor (B4/7) for low-pressure circuit from connection fitting for coolant return line and place to one side | ||
Installation: Ensure that fuel hose (20) is routed correctly. | |||
35 | Remove glow plugs. | ||
36 | Remove hydraulic valve play compensation elements. | ||
Do not remove roller-type rocker arm from valve clearance compensating element. | |||
37 | Unscrew screws (25, 26) and screws (27) in reverse order compared to the tightening sequence. | Tightening procedure for cylinder head bolts | |
| |||
Installation: Lightly oil thread and bolt head contact surface of screws (27) with engine oil. | |||
Screw/bolt, cylinder head to crankcase | |||
Bolt, cylinder head to timing case cover | |||
38 | Remove cylinder head with exhaust manifold and charge-air distributor from crankcase. | ||
Notes on application of flange sealants to seal major assemblies | |||
General information on checking valves, valve seats and valve guides | |||
Installation: Take into account dowel pins (28) for securing cylinder head. | |||
Installation: Fit a new cylinder head gasket on the crankcase. | |||
Installation: Apply a sealing bead in sealing areas (A) between timing case and crankcase. | |||
Installation: Secure timing chain at tensioning rail (30) for better assembly with, at least, one cable tie (29). | |||
Sealant, Loctite 5970, 50 ml | |||
Application gun | |||
| Clean | ||
39 | Clean the sealing surfaces on cylinder head and crankcase. | ||
| |||
Loctite 7200 | |||
Loctite 7063 (400 ml) cleaning spray | |||
40 | Blow out threaded holes of screws (27) in crankcase with compressed air and clean of oil and coolant. | ||
| Check | ||
41 | Check sealing surfaces of cylinder head and crankcase for cracks and evennesses. | Do not rework sealing surfaces of cylinder head and crankcase. | |
42 | Check whether a repair crankcase has been fitted with a repair piston. | If an "R" (50) is stamped on the cylinder head contact surface, the corresponding repair cylinder head gasket must be ordered in EPC. | |
43 | Check length of bolts (27). | ||
Cylinder head bolt | |||
If the screw/bolts (27) are too long, | |||
| |||
Replace screws (27). | |||
44 | Install in the reverse order. | ||
Concluding tasks | |||
45 | Pour in coolant and bleed engine cooling system. | ||
46 | Check engine oil level and correct if necessary. | ||
| |||
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. | |
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. | |
47 | Carry out engine test run and check engine for proper leak tightness and leak tightness. |
003 589 03 37 00
Hose clamp pliers
171 589 00 37 00
Pliers for click clamps
112 589 00 25 00
Application gun
129 589 00 91 00
Record plug
001 589 01 91 00
Set of protective covers
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