a Cylinder head removal and installation AR01.30-B-5800B.

fm 1

AR01.30-B-5800B.fm Cylinder head removal and installation 27.11.98

Enigines 904.918/919/920/924/925/938/957
Enigines 906.924/953/969
1 Air duct
2 Turbocharged air distribution manifold
3 Rocker arm assembly
4 Intake valves bridge
5 Pushrod
6 Injection pipe
7 Linking case
8 Gasket
9 Linking piece
10 Capscrews
11 Shifting lever bracket (truks with for-
ward cab and buses)

B01.30-0002-06
a Cylinder head removal and installation AR01.30-B-5800B.fm 2

12 Exhaust manifold and turbocharger

13 Constant throttle line (Top brake)
14 Stretch bolt
15 Cylinder head
16 Cylinder head gasket
17 Air compressor cooling line
18 Cylinder head guides
19 Injectors fuel return flow line

B01.30-0003-06
a Cylinder head removal and installation AR01.30-B-5800B.fm 3

ed Removing and installing

a Danger! Danger of scalding due to coolant high Depressurize system beforehand, carefully AS20.00-B-0001-01A
temperature opening compensation tank turning cap to the first
notch. Do not remove cap, if engine coolant
temperature is above 90oC.
Use required individual protection equipment - IPE

i Directives referring to coolant. AH20.00-B-2080-01A

1 Drain cooling system. Catch the coolant, replace it if necessary. AP20.00-B-2080B

2 Remove the valve cover. AR01.20-B-5014B

3 Remove the air duct (1). AR09.41-B-8620C

4 Remove the turbocharged air distribution AR09.41-B-8681A

manifold (2).

5.1 Remove capscrews (11) and push bracket Truks with forward cab and buses.
(10) away from cylinder head (15). i Displace bracket (10), together with the shifting
rod, so it does not interfere with cylinder head
removal.

n BA01.30-B-1003-01C

6 Remove the exhaust manifold with AR14.10-B-3915A

turbocharger (12).

7 Remove the injection pipe (6). AR07.15-B-9235A

8 Remove injectors fuel return flow line (19) i Installation: Replace seal washers.
on cylinder head (15).
a Cylinder head removal and installation AR01.30-B-5800B.fm 4

9.1 Remove the constant throttle line (13) from Engines fitted with (Top brake) constant throttle
cylinder head (15). i Installation: Replace seal washers.

10 Disconnect from cylinder head (15), the air

compressor cooling line (17).

11 Remove the linking case (7). i Installation: Replace linking piece (9) and AR20.10-B-1290-02A
gasket (8).

n BA20.10-B-1003-01B

12 Remove rocker arm assembly (3). AR05.00-B-5521A

13 Remove valve bridges (4).

14 Remove pushrods (5). i Installation: Lubricate with engine oil.

15 Remove the stretch bolts (14). i Installation: Oil stretch bolts (14) with engine AR01.30-B-5800-01B
oil and follow the tightening specifications.

l 422 589 00 09 00

n BA01.30-B-1002-01C

16 Remove cylinder head (15) and gasket i Installation: Replace gasket (16) and watch AR01.30-B-5800-11A
(16). its assembly position. Fit gasket and cylinder head
perfectly on guides (18).

l 904 589 01 63 00

p To avoid damage on installed injection noz-

zle assembly, place cylinder head to one side.

17 Clean tapped holes, oil and coolant i Protect crankcase deck from dirt.
passage holes on crankcase.
a Cylinder head removal and installation AR01.30-B-5800B.fm 5

g Checking

18 Measure length (L) of stretch bolts (14). i Replace stretch bolt (14), if maximum BE01.30-B-1001-01C
permissible length (L) is exceeded.

19 Clean cylinder head (15) and check it for i In case of anomaly, replace the cylinder head.
cracks.

20 Check cylinder head (15) mating surface for AR01.30-B-5800-12A

distortion.
Maximum permissible flatness deviation on BE01.30-B-1002-02C
cylinder head (15) mating surface.

k WH58.30-B-1059-12A

i Rework cylinder head mating surface, if AR01.30-B-7162A

flatness deviation is above maximum permissible.

21 Check crankcase deck for distortion. i On crankcases with cylinder liners, the cylinder AR01.40-B-9133-01A
liner collar must be flush or up to 0,04mm below
crankcase deck surface

Flatness deviation of crankcase deck surface. BE01.40-B-1012-02C

k WH58.30-B-1059-12A

22 Install in the reverse order.

a Cylinder head removal and installation AR01.30-B-5800B.fm 6

a Danger! Risk of personal injuries and material
damage when starting the engine with the
transmission engaged. Risk of personal
injuries, when carrying out services with
the engine heated and in operation.
Ensure the transmission is in neutral position. AS00.00-B-0005-01A
Wear appropriate clothing and pay attention to
moving and heated parts of the engine.

23 Run engine. p Do not crank engine for more than 10

consecutive seconds. If engine does not start
within this interval, wait for approximately 30
seconds and crank again.

24 Run engine at idle speed observing oil p Do not accelerate engine until pressure BE18.00-B-1001-01A
pressure gage. gage reads engine oil pressure. The pressure
should re-establish in approximately 10
seconds.

25 Check engine for leaks. i Check engine oil level 5 minutes after engine AP18.00-B-0101B
shutdown.

26 Check coolant level. Re-establish if necessary. AP20.00-B-2010B

Test data of cylinder head bolts

Number Designation Engine 904.918/919/

920/924/925/938/
943/945/957/962,
906.917/918/924/
953/969/975/977

BE01.30-B-1001-01C Cylinder head bolts thread diameter mm 16x2

shank length (L), new bolt mm 148.5 - 149.0

max. shank length (L), for used bolt mm 151

a Cylinder head removal and installation AR01.30-B-5800B.fm 7

Test data of cylinder head

Number Designation Engine 904.918/919/ Engine 906.917/

920/924/925/938/ 918/924/953/969/
943/945/957/962 975/977

BE01.30-B-1002-02C Maximum permissible unevenness of over total length mm 0.05 0.05

cylinder head mating surface
over a length of 150mm mm 0.02 0.02

Test data of crankcase

Number Designation Engine 904.918/919/

920/924/925/938/
943/945/957/962,
906.917/918/924/
953/969/975/977

BE01.40-B-1012-02C Maximum permissible unevenness of over total length mm 0,030

crankcase deck
over a length of 150mm mm 0,015

Oil pressure

Number Designation Engine 904.918/919/

920/924/925/938/
943/945/957/962,
906.917/918/924/
953/969/975/977

BE18.00-B-1001-01A Minimum admissible engine oil at idle speed bar 0.5

pressure
at max. speed bar 2.5
a Cylinder head removal and installation AR01.30-B-5800B.fm 8

n Cylinder head

Number Designation Engine 904.918/919/

920/924/925/938/
943/945/957/962,
906.917/918/924/
953/969/975/977

BA01.30-B-1002-01C Cylinder head bolts to crankcase 1st stage Nm 20

2nd stage Nm 70

3rd stage Nm 170

4th stage Nm 280

5th stage degrees 90 - 100

6th stage degrees 90 - 100

BA01.30-B-1003-01C Shifting lever bracket/air duct cap- Nm 50

screw to cylinder head

n Coolant pump and thermostat

Number Designation Engine 904.918/919/

920/924/925/938/
943/945/957/962,
906.917/918/924/
953/969/975/977

BA20.10-B-1003-01B Coolant pump linking piece to cylinder Nm 25

head
a Cylinder head removal and installation AR01.30-B-5800B.fm 9

422 589 00 09 00 904 589 01 63 00

Cylinder head bolt socket Cylinder head lifting device

Commercially available tools: measuring instruments

Number Designation Make (e.g.) Order number

WH58.30-B-1059-12A Straightedge - -