W01.30-1089-08
1 | Coolant line | 5 | Electrical wiring harness | 9 | Fuel return line | ||
2 | Connection piece | 6 | Connection fitting | 10 | Constant throttle line | ||
3 | Connection fitting | 7 | Bracket | 11 | Injection lines | ||
4 | Coolant pipe | 8 | Cylinder head |
W01.30-1090-08
8 | Cylinder head | 13 | Exhaust manifold | L | Shank length | ||
12 | Cylinder head bolts | 14 | Lifting device |
W01.30-1091-08
Shown on engine 902.9 with code (MS5) BlueTec 5 |
8 | Cylinder head | * | Only for vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5 | 21 | Coolant line connection fitting * | ||
15 | Shield | 18 | Coolant line to compressor | 22 | Electrical wiring harness * | ||
16 | Coolant line | 19 | Lifting eye | 23 | Bracket | ||
17 | Compressor air intake duct | 20 | Resonator | Y107 | SCR tank heater solenoid valve* |
| Remove/install | ||
1 | Switch off ignition | ||
Danger | Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. | No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers. | |
2 | Disconnect ground line from battery | ||
Topical note | Notes on battery | ||
3 | 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. | |
4 | Tilt cab | ||
Topical note | Notes on tilting the cab | ||
Installation: Only tilt back cab after the leak test. | |||
5 | Drain off coolant | ||
6 | Remove exhaust manifold (13) at cylinder head (8) | ||
7 | Remove charge air manifold | ||
8 | Remove rocker arm assembly | ||
9 | Remove coolant pipe (4) at connection piece (2) ad press to side | Do not release coolant hoses. Collect coolant which flows out. | |
Installation: Replace seal. | |||
10 | Remove coolant line (1) at connection piece (2) | Collect coolant which flows out. | |
11 | Expose electrical wiring harness (5) and disconnect at coolant temperature sensor | ||
12 | Unscrew connection fitting (6) | ||
13 | Remove connection piece (2) | Press bracket (7) of crankcase ventilation to side. | |
Installation: Coat new connection fitting (3) with ATE grease. | |||
Bolt, connection piece for coolant pump to cylinder head | |||
ATE brake cylinder paste | |||
14 | Remove constant throttle line (10) at cylinder head (8) | 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. | |
15 | Remove injection lines (11) | Installation: Check injection lines (11), replace if necessary. | |
Injection line to pressure pipe connection and unit pump | |||
Ring wrench | |||
Box wrench bit | |||
16 | Remove fuel return line (9) at cylinder head (8) | Installation: Install new sealing rings. | |
17 | Remove compressor coolant line (18) at cylinder head (8) | Installation: Install new sealing rings. | |
18 | Remove coolant line (16) at shield (15) and press to side | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
19 | Remove compressor air intake line (17) at shield (15) and at resonator box (20) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
20 | Remove resonator box (20) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
21 | Expose electrical wiring harness (22) and disconnect SCR tank heater solenoid valve (Y107) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
22 | Remove coolant line connection fitting (21) at cylinder head (8) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
Installation: Replace seal. | |||
23 | Remove SCR tank heater solenoid valve (Y107) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
24 | Remove bracket (23) at cylinder head (8) | Only in vehicles with code (MS4) BlueTEC 4 or code (MS5) BlueTEC 5. | |
25 | Remove lifting eye (19) at cylinder head (8) | ||
26 | Remove cylinder head bolts (12) | ||
Installation: Observe tightening specification and tightening torque of cylinder head bolts (12). | |||
Cylinder head bolts on crankcase | |||
Socket wrench bit | |||
27 | Lift off cylinder head (8) with lifting device (14) | ||
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Lifting eye of lifting device (14) must point towards exhaust side. | |||
Lifting device | |||
28 | Remove cylinder head gasket | Installation: Install new cylinder head seal. Marking "TOP" must point to cylinder head (8). Take into account centering sleeves in crankcase. | |
29 | Clean cylinder head (8) | ||
Topical note | Information on working sealing surfaces when carrying out engine repairs | ||
30 | Close off all bores on cylinder crankcase contact surface using fabricated stop plugs | ||
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| Check | ||
31 | Check cylinder head sealing surface for cracks and damage, also check cylinder head gasket | ||
Height of cylinder head | |||
Permissible variation in flatness of lower separating surface in a longitudinal direction | |||
32 | Clean and check the contact surface of the cylinder crankcase | | |
33 | Measure shank length (L) of cylinder head bolts (12) | If max. shank length (L) is exceeded, replace corresponding cylinder head bolt (12). | |
Cylinder head bolts | |||
34 | Perform additional inspection work in the case of engine repair at cylinder head (8) and at cylinder head gasket | ||
35 | Install in the reverse order | ||
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. | |
36 | 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 | ||
37 | Switch off engine and check in area of cylinder head (8) for leaks | Visual inspection. | |
38 | Check engine oil level at display; correct if necessary | ||
Notes on engine oil | |||
Observe engine oil grade set in maintenance system or Specifications for Operating Fluids. | |||
39 | Synchronize the time of the tachograph disk record | Only for vehicles with modular tachograph. |
000 589 68 03 00
Box wrench bit
904 589 01 63 00
Lifting device
000 589 07 03 00
Ring wrench
422 589 02 09 00
Socket wrench bit