AR01.30-W-5800A Remove/install cylinder head 22.11.06 ENGINE 904.9 in MODEL 374, 375, 673, 674, 676, 958, 970, 972, 975, 976 ENGINE 906.9 in MODEL 374, 958, 970, 972, 974, 975, 976 ENGINE 906.9 in MODEL 374, 375, 950, 952, 953, 954, 958 ENGINE 906.9 in MODEL 957.5 /6 except CODE (MS8) Natural gas engine Shown on engine 904.9 1 Soundproofing panel 2 Charge air manifold 3 Injection line 4 Rocker arm assembly 5 Valve bridge 6 Tappet rod 7 Seal 8 Connecting piece 9 Bolt 10 Connection fitting 11 Engine wiring harness 12 Coolant line B8 Coolant temperature sensor (model 673, 674, 676) B65 Coolant temperature sensor (model 374, 375, 950, 952, 953, 954, 958, 970, 972, 974, 975, 976) Coolant temperature sensor (model 957) Shown on engine 904.9 W01.30-1060-06 13 Exhaust manifold with turbocharger 14 Constant throttle line 15 Coolant line to compressor 16 Leak fuel line 17 Cylinder head bolt 18 Cylinder head 19 Cylinder head gasket 20 Centering sleeve W01.30-0017-06 Copyright Daimler AG 10/30/10 G/01/08. This WIS printout will not be recorded by the update service. Page 1
Shown on engine 904.9 14 Constant throttle line 21 Lifting device 17 Cylinder head bolt 22 Straightedges 18 Cylinder head 23 Gearshift lever with bracket (only 19 Cylinder head gasket for code (GS1) "Manual" gearshift) 20 Centering sleeve L Shank length W01.30-0018-09 Engine 906.9 with code (GS3) "Hydraulic" gearshift 30 Hydraulic lines 31 Clamps 32 Bracket 33 Bolt W26.60-1011-11 Remove/install Danger! Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A scalding from contact with hot coolant spray. temperature is below 90 C. Open cap slowly Risk of poisoning caused by swallowing and release the pressure. Do not pour coolant. coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. 1 Drain coolant AR20.00-W-1142C Notes on coolant AH20.00-N-2080-01A 2 Remove soundproofing (1) on frame at the rear 3.1 Detach shift lever with bracket (23) at with code (GS1) "Manual" gearshift. cylinder head (18) 3.2 Remove clamps (31) and bracket (32) for with code (GS3) gearshift "hydraulic" hydraulic lines (30) on cylinder head (18) 4 Remove charge air manifold (2) Model 374, 375, 950, 952, 953, 954, 957, AR09.41-W-8681C 958, 970, 972, 974, 975, 976 Models 673, 674, 676 AR09.41-W-8681A Copyright Daimler AG 10/30/10 G/01/08. This WIS printout will not be recorded by the update service. Page 2
5 Remove exhaust manifold with turbocharger AR14.10-W-3915A (13) on cylinder head (18) 6 Remove injection line (3) AR07.15-W-9235A 7 Detach constant throttle line (14) on cylinder head (18) 8 Detach leak fuel line (16) from cylinder head (18) 9 Detach compressor coolant line (15) at cylinder head (18) 10.1 Disconnect engine wiring harness (11) on Model 374, 375, 950, 952, 953, 954, 957, coolant temperature sensor (B65) or on 958, 970, 972, 974, 975, 976 coolant temperature sensor (B65) 10.2 Disconnect engine wiring harness (11) at Models 673, 674, 676 coolant temperature sensor (B8) 11 Remove connection piece (8) at cylinder Transmission 710, 712, 715 AR20.10-W-1290-02A head (18) and at coolant pump Transmission 723 AR20.10-W-1290-02H Installation: Replace connection fitting (10) and gasket (7). *BA20.10-N-1003-01C 12 Remove rocker arm assembly (4) Engine 904.9 up to engine end no. 039739, AR05.00-W-5521A Engine 906.9 up to engine end no. 041955 Engine 904.9 from engine end no. 039740, AR05.00-W-5521C Engine 906.9 from engine end no. 041956 13 Remove tappet rods (6) Installation: Ensure push rods (6) are correctly seated in the tappets. 14 Detach rear lifting eye AR22.00-W-1000-01H Only on model 957. 15 Unscrew cylinder head bolts (17) Installation: Observe tightening AR01.30-W-5800-07A instructions for cylinder head bolts (17). *BA01.30-N-1002-01C *422589020900 16 Lift off cylinder head (18) with the lifting Do not lay cylinder head (18) on the device (21) and take off cylinder head gasket cylinder head separating surface to avoid (19) damaging the installed nozzle holder combinations. Installation: Install new cylinder head gasket (19). Observe labeling on cylinder head gasket (19) and seat of centering sleeve (20). *904589016300 17 Clean threaded holes and oil and coolant Seal oil and coolant drillings at drillings in crankcase crankcase. Checking 18 Clean crankcase sealing surface and check Crankcase flatness *BE01.40-N-1013-02B Straightedge see GOTIS http://gotis.aftersales.daimlerchrysler.com Repair damage crankcase sealing surface if necessary. AR01.40-W-9129A 19 Measure length of shank (L) of cylinder head If maximum shank length (L) is *BE01.30-N-1001-01B bolts (17) exceeded, respective cylinder head bolt (17) must be replaced. 20 Check cylinder head sealing surfaces and AR01.30-W-5800-15B cylinder head gasket (19) Height of cylinder head *BE01.30-N-1001-02B Permissible deviation in flatness *BE01.30-N-1002-02B Straightedge see GOTIS http://gotis.aftersales.daimlerchrysler.com 21 Check flatness of separating surface in the Replace cylinder head (18) or machine it *BE01.30-N-1002-02B longitudinal direction of the cylinder head as necessary: (18) 22 Install in the reverse order Face-grind cylinder head separating surface. AR01.30-W-7162A 23 Fill engine oil circuit AR18.00-W-1600A 24 Check engine oil level using oil dipstick or on Observe engine oil grade set in display, correct if necessary maintenance system or Specifications for Operating Fluids. Copyright Daimler AG 10/30/10 G/01/08. This WIS printout will not be recorded by the update service. Page 3
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. injury caused by contusions and burns Wear closed and snug-fitting work clothes. during starting procedure or when working near the engine as it is running Do not touch hot or rotating parts. 25 Start engine and observe oil pressure gauge Crank engine with the starter for not *BE18.00-N-1001-01C with the engine idling more than 90 s. Repeat starting procedure after a break of approx. 2 min. Do not rev up the engine as long as no oil pressure is indicated. The oil pressure gauge must indicate oil pressure after about 10 seconds. 26 Switch off engine and check for leaks Check values for cylinder head bolts BE01.30-N-1001-01B Cylinder head Thread M bolts 16 2 Length of shank when new mm 149.0 Permissible shank length mm 151.0 Check values for cylinder head Number Designation Engine Engine 900.9, 904.9 902.9, 906.9 BE01.30-N-1001-02B Height of cylinder head when new mm 107.9 to 108.1 107.9 to 108.1 after stock removal mm 106.9 106.9 BE01.30-N-1002-02B Permissible variation in flatness of over the entire length mm 0.05 0.07 lower separating surface in longitudinal direction Over a length of mm 0.02 0.02 150 mm Check values for crankcase Number Designation Engine 904.9, Engine 906.9 without code MS8 BE01.40-N-1013-02B Crankcase - flatness of mating face over the entire length mm 0.030 over a length of 150 mm mm 0.015 in longitudinal and transverse direction Check values for engine oil pressure BE18.00-N-1001-01C Engine oil Idling speed bar pressure at 0.5 Copyright Daimler AG 10/30/10 G/01/08. This WIS printout will not be recorded by the update service. Page 4
maximum speed bar 2.5 Cylinder head BA01.30-N-1002-01C Cylinder head bolts on crankcase Stage 1 Nm 20 Stage 2 Nm 70 Stage 3 Nm 170 Stage 4 Nm 280 Stage 5 90 Stage 6 90 Coolant pump, coolant thermostat BA20.10-N-1003-01C Bolt, connection piece of coolant pump to cylinder head Nm 25 422 589 02 09 00 904 589 01 63 00 Wrench socket Lifting device Copyright Daimler AG 10/30/10 G/01/08. This WIS printout will not be recorded by the update service. Page 5