Remove/install cylinder head

AR01.30-S-5800D

Remove/install cylinder head

9.5.12

 

Remove/install

1

Disconnect battery ground line

AR54.10-S-0005A

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

2

Drain coolant

AR20.00-S-1142A

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

3

Remove injectors (Y20)

AR07.16-S-1000A



*602589003300



*611589013300



*611589006800



*000589266800



*001589760900



Notes on injectors

 Clean injector stems and injectors with a wire brush. Grease injector stems with special grease.

Clean injector recesses with a round brush and cylinder brush, blow out and cover over. Seal injector recesses with pin before cleaning. Set the brush length to 3 mm to clean the seal seat.

 Replace injector rings and Screw/bolts for tensioning clamps.

AH07.16-P-1000-01A

Special grease

*BR00.45-Z-1036-06A

4

Remove coolant hoses on thermostat housing (1)

 Check condition of hose clamps and hoses; replace if necessary.

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

5

Detach fuel lines

6

Remove fuel filter (16)

AR47.20-S-5510B

7

Remove fuel filter bracket (17) on cylinder head (27)



*BA47.20-N-1010-02F

8

Unplug connectors on coolant temperature sensor, rail pressure sensor and pressure regulating valve

 Unclip lines and expose.

9

Remove exhaust manifold (18)

AR14.10-S-3915D

10

Take off engine holder at top right (2)

AR22.10-S-1200B



*001589760900

11

Remove screw/bolt (3) on coolant pipe (4) from cylinder head (27)



*BA20.20-N-1001-01G

12

Take off intake manifold (19)

AR09.20-S-1310D

13

Remove nut (5) on charge air hose (6) from cylinder head (27)

14

Remove cylinder head cover (7)

AR01.20-S-5014D

15

Position piston of cylinder 1 to ignition TDC

Rotate engine at crankshaft. Do not rotate engine at the screw/Screw/bolt, the camshaft sprocket. Do not crank engine back.
 Markings on camshaft/camshaft bearing cap (arrows) must be aligned.

AR01.00-S-0120D

16

Install retaining lock for crankshaft/starter ring gear

AR03.30-S-5000C

17

Remove chain tensioner (8)

AR05.10-S-7800D

18

Remove front cover at cylinder head (10)

AR01.30-S-5700A

19

Remove top slide rail (11)

AR05.10-S-8432C

20

Remove intake camshaft (20) and exhaust camshaft (21)

AR05.20-S-6992C

21

Remove camshaft housing (22)

22

Remove high-pressure pump (12)

 Ensure scrupulous cleanliness.

AR07.02-S-1020A

23

Remove intermediate gear of high pressure pump (23)

AR05.10-S-4650A

24

Unscrew screw/bolts on cylinder head (27) to the timing case cover (24)



*BA01.30-P-1005-01A



*001589760900

25

Slacken cylinder head bolts (26) in stages and unscrew

 Loosen cylinder head bolts (26) in reverse order of the tightening procedure once engine has cooled down.

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01HB

Check cylinder head bolts

AR01.30-P-5800-03HB

 Installation: Oil cylinder head bolts (26) at thread and bolt head contact surface and insert. Tighten cylinder head bolts (26) according to the tightening pattern

Tightening procedure for cylinder head bolts

AR01.30-P-5800-01HB



*BA01.30-P-1007-01A



*001589760900



Adjust

*BE01.30-P-1001-04A

26

Attach engine hoist to the mounting eyes for cylinder head (27)

Load regulator

gotis://H_00.12_04.0

27

Remove cylinder head (27)

 The mounting eyes on the timing case side must not be removed.

 Installation: Lay new cylinder head gasket (28) onto crankcase. Ensure correct seating of fitting sleeves (29) for fixing the cylinder head in place.

 If the pistons/connecting rod have been replaced, refer to 

Measure piston projection

AR03.10-P-7041-01B

28

Clean contact surfaces and threaded holes

Ensure scrupulous cleanliness. The tapped holes must not have any oil and water.

Check contact surfaces,  if necessary

Checking, facing cylinder head contact surface.

AR01.30-P-7162HB

29

Install in the reverse order



Checking

30

Inspect cooling system for leaks

 Engine with new cylinder head gasket:

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-S-1010A

31

Check engine oil level; refill if necessary

AP18.00-D-0101A

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

32

Check for leaks with engine running

33

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Refer to:

Diagnosis manual for diesel engine, Volume 1.2

Number

Designation

Engine
611.980

BE01.30-P-1001-04A

Cylinder head bolt

Thread diameter

M

12

Length (L) when new

mm

102

Max. length (L)

mm

104

See picture

AR01.30-P-5800-03HB

Number

Designation

Engine 611.980

BA01.30-P-1005-01A

Screw/bolt, cylinder head to timing case cover

M8

Nm

20

BA01.30-P-1007-01A

Screw/bolt, cylinder head to crankcase M12

Stage 1

Nm

60

Stage 2

 °

90

Stage 3

 °

90

Number

Designation

Engine
611.980

BA20.20-N-1001-01G

Coolant drain plug to radiator (reference value)

Nm

3

Number

Designation

Engine
611.980/981/983/
987
with code KL5,
engine 612.981 with code KL5

Engine 611.980/981/983/987 without
code KL5,
612.981 without code KL5

BA47.20-N-1010-02F

Bolt and nut for fuel filter bracket on cylinder head

Nm

8

8

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10