Remove/install cylinder head

AR01.30-W-5800J

Remove/install cylinder head

04.12.2019

Engine

900.9 in model 375.1, 970, 972, 975, 976

Engine

902.9 in model 375.1, 970, 972, 974, 975, 976

Engine

902.9 in model 375.3, 950.5/6, 952.5/6, 953.6, 954.5

Engine

924.9 in model 958.0, 970, 972, 974, 975, 976

Engine

925.9 in model 970, 972, 974

Engine

926.9 in model 950.5/6, 952.5/6, 953.6, 954.5, 958.2

Engine

926.9 in model 958.0

Shown on engine 926.9

1

Cylinder head

5

Engine brake valve fitting (only for vehicles with code (MB1) Engine brake with constant throttle)

8

Bracket (only for vehicles with code (GS3) "Hydraulic" gearshift)

2

Exhaust manifold

6

Gearshift lever (only for vehicles with code (GS1) "Manual" gearshift)

9

Coolant pipe (only for vehicles with code (BA1) Performance-optimized Voith retarder or code (BA9) Voith secondary retarder R 115 or for automatic transmission)

3

Engine brake cylinder (only for vehicles with code (MB1) Engine brake with constant throttle)

7

Rocker arm assembly

10

Connection piece

4

Bracket

Shown on engine 926.9

1

Cylinder head

12

Constant throttle line (only for vehicles with code (MB1) Engine brake with constant throttle)

14

Coolant line to compressor

11

Injection lines

13

Fuel return line

Shown on engine 926.9

1

Cylinder head

15

Bracket (only for vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5)

16

Cylinder head bolts

Shown on engine 926.9

1

Cylinder head

18

Electrical wiring harness

20

Lifting device

16

Cylinder head bolt

19

Coolant line connection fitting (only for vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5)

L

Shank length

17

Bracket

 

Remove/install

1

Switch off ignition

2

Disconnect ground line from battery

AR54.10-W-0003A

 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.

AS60.80-Z-0001-01A

3

Tilt cab

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

 Installation: Only tilt back cab after the leak test.

4

Drain coolant at radiator

AR20.00-W-1142J

5

Remove bracket from the metering device of the exhaust aftertreatment system

AR14.40-W-2023J

 Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5.

6

Remove SCR tank heater solenoid valve

AR14.40-W-2010C

 Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5.

7

Remove charge air pipe from ATL to charge air cooler

AR09.41-W-1311JC

8

Remove charge air manifold

AR09.41-W-8681J

9

Remove rocker arm assembly (7)

AR05.00-W-5521J

10

Remove coolant pipe (9) at connection piece (10)

 Only for vehicles with code (BA1) Performance-optimized Voith retarder or with code (BA9) Voith secondary retarder R 115 or for automatic transmission.

 Installation: Replace seal.

11

Remove connection piece (10) between coolant pump and cylinder head (1)

AR20.10-W-1290-02J

 Installation: Replace seal and connection fitting.

 Bolt, connection piece for coolant pump to cylinder head

*BA20.10-N-1003-01C

Long-life grease

*BR00.45-Z-1001-06A

12

Remove engine brake cylinder (3)

AR14.15-W-5816J

 Only for vehicles with code (MB1) Engine brake with constant throttle.
Do not remove compressed air line.

13

Release bracket (4) at engine brake valve fitting (5) and swivel to side

 Only for vehicles with code (MB1) Engine brake with constant throttle.

14

Remove exhaust manifold (2) at cylinder head (1)

 Installation: Clean sealing surfaces and replace seals. Marking "TOP" must point towards exhaust manifold (2).

 Engine 900.9, 902.9, 924.9, 925.9, 926.9Bolt, exhaust manifold to cylinder head

*BA14.10-N-1001-01B

15

Remove gearshift lever (6) with holder at cylinder head (1)

 Only for vehicles with code (GS1) "Manual" gearshift.

16

Remove bracket (8) of hydraulic lines at cylinder head (1)

 Only for vehicles with code (GS3) "Hydraulic" gearshift.

17

Remove constant throttle line (12) from cylinder head (1)

 Only for vehicles with code (MB1) Engine brake with constant throttle.

 Installation: Install new sealing rings.

 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

18

Remove injection lines (11)

 Installation: Check injection lines (11), replace if necessary. Pay attention to installation position.

 Ring wrench

*000589070300

 Box wrench bit

*000589680300

19

Remove fuel return line (13) from cylinder head (1)

 Installation: Install new sealing rings.

20

Remove compressor coolant line (14) at cylinder head (1)

 Installation: Install new sealing rings.

21

Remove bracket (15) at cylinder head (1)

 Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5.

22

Expose electrical wiring harness (18)

23

Remove coolant line connection fitting (19) from cylinder head (1)

 Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5.

 Installation: Clean sealing surfaces and replace gasket.

24

Remove bracket (17) from cylinder head (1)

 Installation: Attach screws of bracket (17) and of exhaust manifold (2) at the same time.

25

Remove cylinder head bolts (16)

AR01.30-W-5800-07A

 Installation: Observe tightening specification and tightening torque of cylinder head bolts (16).

 Cylinder head bolts on crankcase

*BA01.30-N-1002-01C

 Socket wrench bit

*422589020900

26

Lift off cylinder head (1) using lifting device (20)



BT05.30-N-0004-01RH


Set aside cylinder head (1),
as installed nozzle holder assemblies will otherwise be damaged.

 Lifting eye of lifting device (20) must point towards exhaust system.

 Lifting device

*904589016300

27

Remove cylinder head gasket

 Installation: Install new cylinder head seal. The marking "TOP" must point towards the cylinder head (1). Take into account centering sleeves in crankcase.

28

Clean cylinder head (1)

Topical note

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

29

Close off all bores on cylinder crankcase contact surface using fabricated stop plugs



WF58.50-W-0100-04A



Check

30

Check cylinder head sealing surface for cracks and damage, also check cylinder head gasket

AR01.30-W-5800-15B

Height of cylinder head

*BE01.30-N-1001-02B

Permissible variation in flatness of lower separating surface in a longitudinal direction

*BE01.30-N-1002-02B

31

Clean and check the contact surface of the cylinder crankcase


No contamination may get into bores for engine oil, coolant, pushrods and cylinder head bolts (16) or into cylinders.
Otherwise, engine damage can occur.

32

Measure length of shank (L) of cylinder head bolts (16)

 If max. shank length (L) is exceeded, replace corresponding cylinder head bolt (16).

Cylinder head bolts

*BE01.30-N-1001-01B

33

Measure shank length of exhaust manifold bolts

 If max. shank length is exceeded, replace corresponding exhaust manifold screw.

Engine 900.9, 902.9, 924.9, 925.9, 926.9Exhaust manifold bolts

*BE14.10-N-1001-01A

34

Carry out additional test works after engine repair on cylinder head (1) and cylinder head gasket

Engine 900.9, 902.9, 924.9, 925.9, 926.9

AR01.10-W-0003J

35

Install in the reverse order

36

Fill engine oil circuit

AR18.00-W-1600J

 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.

AS00.00-Z-0005-01A

37

Start engine and allow to run in idle for 10 s until the oil pressure has built up, then run the engine at varying speeds

38

Turn off engine and check area of installed cylinder head (1) for leaktightness

 Visual inspection.

39

Check engine oil level at display; correct if necessary

Notes on engine oil

AH18.00-N-0101-01HA

 Observe engine oil grade set in maintenance system or Specifications for Operating Fluids.

Check values for cylinder head bolts

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BE01.30-N-1001-01B

Cylinder head bolts

Thread

M

162

162

Length of shank when new

mm

149,0

149,0

Permissible shank length

mm

151,0

151,0

Check values for cylinder head

Number

Designation

ENGINE 900.9, 904.9

ENGINE 902.9, 906.9

BE01.30-N-1001-02B

Height of cylinder head

New

mm

107,9...108,1

107,9...108,1

after stock removal

mm

106,9

106,9

Check values for cylinder head

Number

Designation

ENGINE 924.9

ENGINE 925.9, 926.9

BE01.30-N-1001-02B

Height of cylinder head

New

mm

107,9...108,1

107,9...108,1

after stock removal

mm

106,9

106,9

Check values for cylinder head

Number

Designation

ENGINE 900.9, 904.9

ENGINE 902.9, 906.9

BE01.30-N-1002-02B

Permissible variation in flatness of lower separating surface in a longitudinal direction

over the entire length

mm

0,05

0,07

Over a length of 150 mm

mm

0,02

0,02

Check values for cylinder head

Number

Designation

ENGINE 924.9

ENGINE 925.9, 926.9

BE01.30-N-1002-02B

Permissible variation in flatness of lower separating surface in a longitudinal direction

over the entire length

mm

0,05

0,07

Over a length of 150 mm

mm

0,02

0,02

Check values for exhaust manifold

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BE14.10-N-1001-01A

Exhaust manifold bolts

Thread diameter

M

10

10

Length of shank when new

mm

47,0

47,0

Permissible shank length

mm

47,5

47,5

 Cylinder head

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA01.30-N-1002-01C

Cylinder head bolts on crankcase

Stage 1

Nm

20

20

Stage 2

Nm

70

70

Stage 3

Nm

170

170

Stage 4

Nm

280

280

Stage 5

°

90

90

Stage 6

°

90

90

 Exhaust manifold

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA14.10-N-1001-01B

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

10

Stage 2

Nm

55

55

Stage 3

°

90

90

 Coolant pump, coolant thermostat

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA20.10-N-1003-01C

Bolt, connection piece for coolant pump to cylinder head

Nm

50

50

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11