AR01.30-P-5800HC Remove/install cylinder head 30.11.

98

ENGINE 612.961 /963

P01.30-2055-09
Illustrated on Engine 612.961

P01.30-2053-09
Illustrated on Engine 612.961

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 P01.30-2054-09
Illustrated on Engine 612.961

Modification notes

25.7.00 Classification of injectors, included for the first time Step 12

5.2.02 Value modified from 22 Nm to 20 Nm Value in line BA07.16-P-1002-01A on Engine *BA07.16-P-1002-01A
612.961/963 revised
5.2.02 Value modified from 22 Nm to 20 Nm Value in line BA07.16-P-1002-01A for engine *BA07.16-P-1002-01A
613.960/961 modified
25.9.03 Value changed from 20 Nm to 23 Nm Value in series 1002 modified for engine *BA07.16-P-1002-01A
612.961/963

ed Remove/Install
a Danger! Risk of injury to fingers being jammed or When moving components, ensure that no body AS00.00-Z-0011-01A
pinched when Remove/install or aligning hoods, parts or limbs are within the operating range of
doors, trunk lid/tailgate or sliding roof. moving parts.
1 Open engine hood and position upright Engine 612.963 in Model 163 AR88.40-P-1000GI

p Have assistant secure hood.

2 Disconnect ground cable of battery AR54.10-P-0003A

3 Remove bottom section of sound-proofing Engine 612.961 AR94.30-P-5300AB

capsule
Engine 612.963
a Danger! Risk of injury to skin and eyes suffering 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 from swallowing coolant. and release the pressure. Do not pour coolant
into beverage bottles.
Wear protective gloves, protective clothing and
eye protection.
4 Drain coolant Engine 612.961 AR20.00-P-1142HB

i At radiator and crankcase.

Engine 612.963 AR20.00-P-1142M

i At radiator.

5 Remove trim panels of the cylinder head cover AR01.20-P-5014-02B

(1, 2)
n *BA01.20-P-1002-01A
n *BA01.20-P-1003-01A

6 Remove air cleaner housing AR09.10-P-1050C

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 7 Detach coolant hoses at coolant thermostat p Inspect condition of hose clamps and hoses,
housing replace if necessary.
k *WH58.30-Z-1001-06A
k *WH58.30-Z-1002-06A

8 Detach air intake hose (4/2) at turbocharger (110)

9 Detach vacuum hose (3) at turbocharger
vacuum unit (110/10)
10 Detach coolant expansion reservoir from body Engine 612.963
i Do not detach lines. Place reservoir over
engine for removing injectors.
a Danger! Risk of explosion if ignition takes place, risk of No fire, sparks, naked flames or smoking. AS47.00-Z-0001-01A
poisoning caused by inhaling fuel vapors or Pour fuels only into suitable and appropriately
swallowing fuel as well as risk of injury to skin marked containers.
and eyes exposed to fuel. Wear protective clothing when handling fuel.
11 Remove injectors (Y76) AR07.16-P-1000HB
l Impact extractor *602589003300
l Extraction claw *611589003300

12 Clean injectors (Y76) p Seal injector recesses with pin before

cleaning.
Clean injector stems and injector recesses with
fleece cloth.
Clean nozzle tips only with non-woven cloth.
Clean injector recesses with round and cylinder
brush, blow out, clean with fleece cloth and
cover up.
Clean injector stems with a wire brush and non-
woven cloth and grease with special grease.
p Only install screws in combination with
forged clamping claws.
p Replace injector seal and screws of
tensioning clamps.
l Round brush *611589006800
l Cylinder brush *668589006800
l Brake caliper brush *000589266800
Special grease *BR00.45-Z-1043-06A

p Notes on injectors Engine 611.960/961/981/987, AH07.16-P-1000-01A

612.961/963/981, 613.960/ 961, 668.940
i Injector Classification Engine 611.960/ 961/ 962, 912961/ 962 AH07.16-P-1001-01B

13 Remove cylinder head cover (6) AR01.20-P-5014HB

14 Position piston of cylinder 1 to ignition TDC p Rotate engine at crankshaft. Do not rotate
engine at the bolt of the camshaft sprocket. Do
not crank engine back.
i Marking of camshaft and camshaft bearing
cap (arrows) must be aligned.
15 Install retaining lock for crankshaft/starter ring AR03.30-P-5000HB
gear
16 Remove chain tensioner (4) p Replace seal of chain tensioner (5) AR05.10-P-7800HB

17 Remove front cover (7) at cylinder head AR01.30-P-5700B

18 Remove top guide rail (8) AR05.10-P-8432B

19 Remove camshafts (9, 10) AR05.20-P-6992HB

20 Remove camshaft housing (11)

21 Remove intermediate gear (24) AR05.10-P-4650A

22 Remove pressure line (19/1) at high pressure n *BA07.16-P-1002-01A

pump (19)
23 Remove fuel return flow line between rail and
high pressure pump
24 Remove high pressure pump (19) p Installation: Install new O-ring. AR07.02-P-1020HB

25 Separate electrical connections at the cylinder p At glow plugs, coolant temperature sensor,
head rail pressure sensor and pressure control valve.
Detach attached cables and place to the side.
26 Remove main fuel filter (70) Engine 612.961 AR47.20-P-1070HB
Engine 612.963 AR47.20-P-1070M

27 Remove charge air distribution pipe (110/1) i Rail remains attached at cylinder head. AR09.41-P-1310HB

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 28 Unbolt bracket (22, 23) at cylinder head i At guide tube for engine oil dipstick and gear
oil dipstick
n *BA18.40-P-1001-01D

29 Disconnect precatalytic converter (120/1) at p Removal, installation: Detach precatalytic

turbocharger (110) converter at fixtures.
i Turbocharger and exhaust manifold remain
attached at cylinder head.
n *BA09.40-P-1002-01C

30 Detach charge air pipe (110/6) at turbocharger n *BA09.41-P-1002-01A

31 Remove oil return flow line (110/4) at turbochargerp Installation: Install new gaskets.
n *BA09.40-P-1003-01C

32 Take off bracket (13) at turbocharger n *BA09.40-P-1006-01C

33 Unscrew bolts (14) of cylinder head at timing p Installation: Tightening pattern of bolts (14)
case cover and (15) observe.
n *BA01.30-P-1001-01M

34 Slacken cylinder head bolts (15) in stages, p Slacken cylinder head bolts in reverse order
unscrew of tightening diagram once engine has cooled
down. See
Tightening diagram of cylinder head bolts AR01.30-P-5800-01HC

p Installation: Oil and insert cylinder head

bolt at thread and bolt head contact surface It is
not necessary to retighten the cylinder head bolts.
n *BA01.30-P-1003-01M

35 Inspect cylinder head bolts (15) AR01.30-P-5800-03HB

*BE01.30-P-1001-04A

36 Remove cylinder head (16) p Installation: Place new cylinder head

gasket (18) on crankcase.
i When remounting the top, align with fitted
bushings (20) for lining up the cylinder head.
p If the pistons/connecting rods have been
replaced, See
Measure piston projection AR03.10-P-7041-01B
k *WH58.30-Z-1001-07A

37 Clean contact surfaces and threaded holes p Blow out threaded holes, free of oil and
water. Inspect contact surfaces. See
Checking, facing cylinder head contact surface AR01.30-P-7162HB

38 Remove oil from cooling and heating system If oil present in cooling and heating system AR20.00-P-1250B

39 Install in the reverse order

40 Inspect cooling system for leaks p Engine with new cylinder head gasket: AR20.00-P-1010HA
Do not pressure-test cooling system until engine
has reached operating temperature.
a Danger! Risk of accident. Accidents may result if the Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A
vehicle starts off unintentionally with the engine Wear closed and snug-fitting work clothes.
running. Risk of injury as working around the Do not grasp hot or rotating parts.
engine during start-up or while running may
result in contusions and burns
41 Run engine and inspect for oil leaks
a Danger! Risk of explosion from fuel igniting. Risk of Keep all ignition sources out of hazardous area. AS07.16-Z-0001-01A
injury. Fuel may stream out and cause injury to Do not carry out any work on the system when it
eyes or skin.
is pressurized.
42 Run engine and inspect fuel system for leaks
43 Read diagnostic trouble code memory and erase Stored faults possibly caused by previous
simulation or by cables disconnected in the
process of installation or testing must be
processed and erased in the DTC memories
once all work is completed. See
STAR DIAGNOSIS

Cylinder head/cylinder head bolts

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 Number Designation Engine 612.961/
963/965/966

BE01.30-P-1001-04A Cylinder head bolt Thread diameter M 12

Length (L) when new mm 102

max. length (L) mm 104
Fig. see AR01.30-P-5800-03HB

n Crankcase ventilation, cylinder head cover

Number Designation Engine Engine

612.961/ 612.963
962/967

BA01.20-P-1002-01A Screw of trim panel of cylinder head cover to Nm 10 10

cylinder head cover

BA01.20-P-1003-01A Screw attaching cover panel to charge air Nm 10 10

distribution pipe

n Cylinder head tightening torques

Number Designation Engine

612.961/962/963/9
65/966/967/981

BA01.30-P-1001-01M Bolt of cylinder head to timing case cover M8 Nm 20

BA01.30-P-1003-01M Bolt of cylinder head to crankcaseM12 1st stage Nm 60

2nd stage Nm -
2nd stage ° 90
Step 3 ° 90
4th stage ° -
5th stage ° -

n Common rail diesel injection (CDI)

Number Designation Engine

612.961/
963

BA07.16-P-1002-01A Nut of pressure line to high pressure pump/rail Nm 23

n Turbocharger

Number Designation Engine

612.961/
963

BA09.40-P-1002-01C Connection of turbocharger to front catalytic converter Nm 30

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 BA09.40-P-1003-01C Bolt of oil outlet line to turbocharger Nm 9

BA09.40-P-1006-01C Bolt of support to turbocharger Nm 30

n Charge air pipe/charge air cooling

Number Designation Engine

611.960/961/962
612.961/962/963/
613.960/961

BA09.41-P-1001-01A Bolt to charge air distribution pipe M5 Nm -

M7 Nm 16

BA09.41-P-1002-01A Hose clamps of charge air pipes/hoses Nm 3

BA09.41-P-1003-01A Bolt to charge air cooler Nm -

BA09.41-P-1004-01A Bolt of support to charge air distribution pipe Nm 20

BA09.41-P-1005-01A Bolt of support to engine bracket Nm 40

n Oil level/oil pressure sensor

Number Designation Engine

612.961/
963

BA18.40-P-1001-01D Bolt of dipstick guide tube to cylinder head Nm 14

602 589 00 33 00 611 589 00 33 00 611 589 00 68 00 000 589 26 68 00

Impact extractor Extraction claw Round brush Brake caliper brush

668 589 00 68 00

Cylinder brush

Commercially available tools

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 Number Designation Make (e. g.) Order number
WH58.30-Z-1001-06A 6 mm socket hexagon of flexible shaft for hose clamps with worm drive Hazet 426-6
Güldenwerther
Bahnhofstraße 25-28
D-42857 Remscheid
WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive Hazet 426-7
Güldenwerther
Bahnhofstraße 25-28
D-42857 Remscheid
WH58.30-Z-1001-07A Engine hoist (self-locking) Bäcker 3188
Herderstraße
D-42853 Remscheid

Auxiliary repair materials

Number Designation Order number

BR00.45-Z-1043-06A Special grease 001 989 42 51 10

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