Modification notes |
15.02.2008 | Reference divided and validities added. | Operation steps 15, 29 | |
01.01.1970 | Engine 541.9, engine 542.9 with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5 | AR14.10-W-3915GA | |
01.01.1970 | Engine 542.9 without code (MS4) BlueTec 4 or without code (MS5) BlueTec 5 | AR14.10-W-3915GB |
Shown on engine 541.9 |
1 | Cylinder head seal |
2 | Cylinder head |
3 | Injection line |
4 | Leak fuel line |
5 | Push rod |
6 | Rocker arm assembly |
7 | Valve bridge |
8 | Cylinder head bolt |
9 | Constant throttle line |
10 | Constant throttle line |
11 | Seal |
12 | Exhaust manifold |
13 | Spring pin |
14 | Dowel pin |
L | Shank length |
W01.30-1038-06
| Remove | ||
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. | |
Topical note | Notes on coolant | ||
1 | Switch off ignition | ||
2 | Open maintenance flap | ||
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
3 | Tilt cab | ||
Topical note | Notes on tilting the cab | ||
4 | Remove soundproofing from frame on the upper left and right | ||
5 | Partially drain coolant at radiator | ||
6 | Remove charge air housing | ||
7 | Remove the clamps of the steering oil return line and steering oil pressure line from the brackets | Only when removing cylinder heads from the left-hand side of the engine. | |
8 | Remove leak fuel line (4) from affected cylinder head (2). | In addition, remove leak fuel line (4) from cylinder head located in front of affected cylinder head and push away leak fuel line (4). | |
9 | Remove injection line (3) from affected cylinder head (2). | ||
10 | Remove cylinder head cover from affected cylinder head (2). | ||
11 | Remove rocker arm assembly (6) from affected cylinder head (2). | ||
12 | Remove valve bridges (7) | ||
13 | Pull out push rods (5) | Turn push rods (5) during removal so that these detach in roller tappets and roller tappets are not pulled out of cylinder crankcase. | |
14 | Remove constant throttle lines (9, 10) from affected cylinder head (2) | ||
15 | Remove exhaust manifold (12) from affected cylinder head bank |
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Engine 542.9 except code MS4 (BlueTec 4), or except code MS5 (BlueTec 5) | |||
16 | Unscrew cylinder head bolts (8) and remove cylinder head (2) | | |
17 | Remove cylinder head gasket (1) | ||
18 | Clean cylinder head (2) | Only scrape off cylinder head sealing surface during cleaning. Do not rub it with an emery cloth. | |
19 | Close off all bores on cylinder crankcase contact surface using fabricated stop plugs | ||
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| Check | ||
20 | Check cylinder head sealing surface and cylinder head gasket (1) | ||
Height of cylinder head | |||
Permissible variation of flatness of lower separating surface | |||
If the cylinder head (2) is warped or cracked, or if the cylinder head gasket (1) is not gastight, | |||
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it is advisable to replace a cylinder head without inductive hardening with a new cylinder head with inductive hardening. In the case of a cylinder head with inductive hardening, the cylinder head (2) must be replaced. | |||
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21 | Clean and check the contact surfaces of the cylinder crankcase and of the cylinder head (2) | | |
Only scrape off sealant and paint residue from the contact surface, do not rub it with an emery cloth. | |||
22 | Check cylinder head bolts (8) | If the permissible shank length (L) is exceeded, the cylinder head bolt (8) involved must be replaced. | |
Cylinder head bolts M182 | |||
23 | Check dowel pins (14) for damage. | If a dowel pin (14) is damaged, both dowel pins (14) must be pulled out with a pliers and replaced with new dowel pins (14). | |
24 | Pull stop plug carefully out of all bores of the cylinder crankcase | ||
25 | Check the seat of the roller tappets in the cylinder crankcase | ||
| Install | ||
26 | Place the new cylinder head gasket (1) onto the contact surface of the cylinder crankcase via the dowel pins (14) | Observe installation position of cylinder head gasket (1). | |
27 | Mount cylinder head (2) on cylinder head gasket (1) using the dowel pins (14). | ||
28 | Tighten the cylinder head (2). | ||
Oil the contact surface, thread and shank of the cylinder head bolts (8) with engine oil. | |||
Cylinder head bolts M182 | |||
Cylinder head bolt to crankcase | |||
Socket wrench bit | |||
29 | Install the exhaust manifold (12) |
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Engine 542.9 except code MS4 (BlueTec 4), or except code MS5 (BlueTec 5) | |||
30 | Attach constant throttle lines (9, 10) to cylinder head (2). | Install new sealing rings. | |
Air line of constant throttle to cylinder head | |||
31 | Install push rods (5) | Lubricate push rods (5) with engine oil and ensure they are seated correctly in the roller tappets. | |
32 | Insert valve bridges (7). | ||
33 | Install rocker arm assembly (6). | ||
34 | Install cylinder head cover | ||
35 | Attach leak fuel line (4) | Install new sealing rings. | |
Leak fuel line to cylinder head | |||
36 | Install injection line (3) | ||
37 | Install charge air housing | ||
38 | Attach clamps of the steering oil return line and the steering oil pressure line to the brackets | Only if there are cylinder heads on the left-hand side of the engine. | |
39 | Perform additional inspection work after engine repair at cylinder head (2) and at cylinder head gasket (1). | ||
40 | Check engine oil level with oil dipstick or on display, add oil if necessary | ||
Notes on engine oil | |||
Observe engine oil grade set in maintenance system or Specifications for Operating Fluids. | |||
41 | Pour in coolant | ||
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. | |
42 | Start engine and allow to run in idle for 10 until the oil pressure has built up, then run the engine at varying speeds | The fuel system is bled automatically. | |
If engine fails to start or only runs for a brief period: | |||
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Purge fuel system by hand. | |||
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43 | Turn off engine and check area of installed cylinder head (2) for leaktightness | Visual inspection. | |
44 | Install soundproofing on frame on the upper left and right | ||
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
45 | Tilt back cab | ||
Topical note | Notes on tilting the cab | ||
46 | Close maintenance flap |
422 589 02 09 00
Socket wrench bit