AR01.30-G-5800CH Remove/install cylinder head 24.02.

2022

Engine 457.9, 458.9 in model 000.001

Modification notes
14.06.2018 Permissible deviation in flatness of lower BE01.30-N-1002-02N
contact surface in longitudinal direction
17.06.2018 Work procedure completely revised.

1 Cylinder head
2 Constant throttle line
3 Constant throttle line
4 Coolant bleed line
5 Cylinder head bolt
6 Rocker arm assembly
7 Valve bridge
8 Leak fuel line
9 Push rod
10 Cylinder head seal
11 Pilot bushing
L Shank length

W01.30-1058-06

Shown on engine 457.9 with BlueTEC

2 Constant throttle line
12 Clip
13 Screw
14 Clamp (only for engines with BlueTEC)
15 Compressed-air line (only for engines with BlueTEC)
16 Coolant line (only for engines with BlueTEC)
17 Lifting eye at the rear
A Angles

G01.30-3154-11

Risk of explosion caused by fuel No fires, sparks, open flames or AS47.00-N-0001-01KOA

aDanger
igniting, risk of poisoning caused by smoking. Pour fuels into suitable and
inhaling and swallowing fuel as well as appropriately marked containers only.
risk of injury to eyes and skin caused
Wear protective clothing when
by contactwith fuel.
handling fuel.
Risk of accident from vehicle Secure vehicle to prevent it moving AS00.00-N-0005-01KOA
aWarning
starting off by itself when engine off. Wear closed and close-fitting work
running. Risk of injury (bruises and clothes. Do not touch hot or rotating
burns) resulting from working on the parts.
engine while it is being started or
when it is running.
Risk of injury to skin and eyes Do not open cooling system unless AS20.00-N-0001-01KOA
aWarning
suffering scalding from contact with coolant temperature is below 90 °C.
Open cap slowly and release the
© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 1/7
 hot coolantspray. Risk of poisoning overpressure. Do not pour coolant into
from swallowing coolant. beverage containers.
Wear protective gloves, protective
clothing and safety glasses.
Risk of injury to skin and eyes due Wear protective gloves, protective AS18.00-N-0001-01KOA
aCaution
to handling of engine oil. Risk of clothing and safety glasses.
poisoning caused by swallowing
Do not fill engine oil into beverage
engine oil
containers.
Notice Notes on threaded connections AH00.00-N-0020-01KOA
fastened using a tightening angle-
based tightening process
Notice Notes on avoiding damage through AH00.00-N-5000-01H
contamination and foreign objects
Notice Information on working sealing AH01.10-N-0002-01A
surfaces when carrying out engine
repairs

e Remove
1 Drain off coolant. i See information from body
manufacturer.
2 Switch off ignition.
3 Remove exhaust manifold. Without turbobrake. AR14.10-G-3006CH
With turbobrake. AR14.10-G-3006CHA
4 Remove coolant bleed line (4) at all
cylinder heads (1) and tie to one side.
5 Remove clamp (12) of constant
throttle line (2) at rear lifting eye (17).
6 Remove constant throttle line (2) at
connection fitting.
7 Remove clamp (14) of compressed-air Only for BlueTEC.
line (15) and coolant line (16) at rear Only at cylinder head (1) of cylinder 6 .
lifting eye (17).
8 Release screws (13) and push rear Only for BlueTEC.
lifting eye (17) away from cylinder Only at cylinder head (1) of cylinder 6 .
head (1) until angle piece (A) is no
longer in contact with cylinder head
(1).
i Do not bend and/or damage lines
attached to rear lifting eye (17).
9 Remove constant throttle line (3) at all
cylinder heads (1).
10 Remove charge-air distributor. AR09.41-G-8681CH
11 Remove injection line at affected AR07.15-G-8971CH
cylinder head (1).
12 Remove leak fuel line (8) at affected i In addition, remove leak fuel line
cylinder head (1). (8) at cylinder heads (1) located in
front of and behind affected cylinder
head and push away leak fuel line (8).
13 Remove cylinder head cover at AR01.20-G-5014CH
affected cylinder head (1).
14 Remove rocker arm assembly (6) at AR05.00-G-5521CH
affected cylinder head (1).
15 Remove valve bridges (7).
16 Remove pushrods (9).
17 Remove cylinder head bolts (5). l Wrench socket 422 589 01 09 00
18 Remove cylinder head (1) and set p
aside. Always set aside cylinder head (1).
Installed nozzle holder assembly will
otherwise be damaged.
19 Remove cylinder head gasket (10)
from crankcase.

m Clean
20 Seal all bores at crankcase sealing
surface with self-fabricated stop plugs.
y Stop plugs for closing off bores WF58.50-W-0100-04A
21 Clean sealing surfaces at exhaust
manifold.

© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 2/7

22 Clean contact surface of cylinder head p
(1) using high-performance disc. Rinse bores of cylinder head (1) after
cleaning with brake cleaner and then
blow out well with compressed air.
Otherwise there will be engine
damage/bearing damage shortly after
the repair.
i Clean only with a scraper or high-
performance bristle disc.
Assembly cleaner BR00.45-N-1028-04KOP
3M Bristle DiscTM high-performance BR00.45-N-1074-04KOP
disc Ø 115 mm, color white (fine), art.
no.: 24539
23 Clean crankcase sealing surface and i Clean only with a scraper or high-
cylinder head sealing surface. performance bristle disc.
3M Bristle DiscTM high-performance BR00.45-N-1074-04KOP
disc Ø 115 mm, color white (fine), art.
no.: 24539
24 Carefully remove self-fabricated stop
plugs from all crankcase bores.
25 Rinse all bores in cylinder head Assembly cleaner BR00.45-N-1028-04KOP
(1) with cleaner and blow out with
compressed air.
26 Blow out all threaded holes of cylinder
head bolts (5) in crankcase with
compressed air.

g Check
27 Check oil scraper ring in cylinder liner Only if installed.
for carbonization.
If significant carbonization is present,
↓
remove oil scraper ring, remove
carbonization and reinstall oil scraper
ring.
28 Check cylinder head sealing surface AR01.30-G-5800-15CH
and cylinder head gasket (10).
Height of cylinder head BE01.30-N-1001-02N
Permissible deviation in flatness of BE01.30-N-1002-02N
lower contact surface in longitudinal
direction
29 Check crankcase sealing surface for If damage exists,
damage.
↓
Replace crankcase.
30 Check cylinder head bolts (5) for AR01.30-G-5800-03CH
damage and measure shank length
(L).
Cylinder head bolts M15×2 BE01.30-N-1001-01M
31 Check pushrods (9) for deformation i Visual inspection.
and damage.
If deformation or damage is present at
socket or at ball head,
↓
replace corresponding pushrod (9).

d Install
32 Mount new cylinder head gasket (10) i Observe installation position of
over pilot bushings (11) on crankcase cylinder head gasket (10).
sealing surface.
33 Mount cylinder head (1) over pilot
bushings (11) on cylinder head gasket
(10).
34 Wet contact surface, thread and shank
of cylinder head bolts (5) with clean
engine oil.
35 Tighten cylinder head bolts (5) at AR01.30-G-5800-07CH
cylinder head (1).
i Observe tightening specifications
for cylinder head bolts (5).
BA01.30-N-1001-01O
n Cylinder head bolt on crankcase
l Wrench socket 422 589 01 09 00
36 Wet pushrods (9) with clean engine oil i Observe seat of pushrods (9) in
and install. roller tappets.
37 Insert valve bridges (7).

© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 3/7

38 Install rocker arm assembly (6) at AR05.00-G-5521CH
cylinder head (1).
39 Install cylinder head cover at cylinder AR01.20-G-5014CH
head (1).
40 Attach leak fuel line (8) at cylinder i Install new sealing rings.
head (1).
BA01.30-N-1005-01O
n Leak oil line for fuel on cylinder
head
41 Install injection line at cylinder head AR07.15-G-8971CH
(1).
42 Install charge-air distributor. AR09.41-G-8681CH
43 Install constant throttle line (3) at all i Install new sealing rings.
cylinder heads (1).
BA01.30-N-1004-01O
n Compressed air line for constant
throttle on cylinder head
44 Tighten screws (13) at rear lifting eye Only for BlueTEC.
(17). Only at cylinder head (1) of cylinder 6 .
i Do not bend and/or damage lines
attached to rear lifting eye (17).
BA22.10-N-1006-01V
n Bolt, rear engine suspension lug to
crankcase
45 Install clamp (14) of compressed-air Only for BlueTEC.
line (15) and coolant line (16) at rear Only at cylinder head (1) of cylinder 6 .
lifting eye (17).
BA22.10-N-1008-01V
n Bolt, clamp to rear engine
suspension lug
46 Install constant throttle line (2) at
connection fitting.
47 Install clamp (12) of constant throttle BA22.10-N-1008-01V
n Bolt, clamp to rear engine
line (2) at rear lifting eye (17).
suspension lug
48 Install coolant bleed line (4) at all BA01.30-N-1002-01O
n Connection fitting, coolant vent line
cylinder heads (1).
to cylinder head
BA01.30-N-1003-01O
n Banjo bolt, coolant vent line to
connection fitting
49 Install exhaust manifold. Without turbobrake. AR14.10-G-3006CH
With turbobrake. AR14.10-G-3006CHA
50 Perform additional inspection work AR01.10-G-0003CH
after engine repair at cylinder head (1)
and at cylinder head gasket (10).
51 Fill in coolant.
g Coolant specifications BB00.40-N-0310-01KOP

i See information from body

manufacturer.
52 Start engine and allow to run in idle If engine fails to start or only runs for a
for about 10 s until the oil pressure brief period,
has built up, then run the engine at
varying speeds.
↓
Bleed fuel system.
AR47.00-G-1720CI
53 Switch off engine and check area i Visual inspection.
of the cylinder head (1) for leak
tightness.
54 Check and correct engine oil level. i Check engine oil level after waiting
at least 5 min. after switching off the
engine.
BF18.00-N-1001-01K
j Engine oil

Check values for cylinder head bolts

Number Designation Engine 457.9,
458.9, 541.9,
542.9, 941.9,
942.9
BE01.30-N-1001-01M Cylinder head bolts M15×2 Length of shank when mm 210
new
Permissible shank length mm ≤212

© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 4/7

Check values for cylinder head
Number Designation Engine 457.9, Engine 457.9,
458.9, 541.9, 458.9, 541.9,
542.9, 941.9, 542.9, 941.9,
942.9 in model 942.9 in model
000.001 000.001
without with inductive
inductive hardening on
hardening on cylinder head
cylinder head
BE01.30-N-1001-02N Height of cylinder head New mm 113,85...114,15 113,85...114,15
after stock removal mm ≥113,5 –

Check values for cylinder head

Number Designation Engine 457.9, Engine 457.9,
458.9, 541.9, 458.9, 541.9,
542.9, 941.9, 542.9, 941.9,
942.9 in model 942.9 in model
000.001 000.001
without with inductive
inductive hardening on
hardening on cylinder head
cylinder head
BE01.30-N-1002-02N Permissible deviation in flatness of lower contact surface in mm ≤0,1 ≤0,1
longitudinal direction

n Cylinder head
Number Designation ENGINE 457.9,
458.9
BA01.30-N-1001-01O Cylinder head bolt on crankcase Stage 1 Nm 10
Stage 2 Nm 50
Stage 3 Nm 100
Stage 4 Nm 200
Stage 5 ∡° 90
Stage 6 ∡° 90

n Cylinder head
Number Designation ENGINE 457.9,
458.9
BA01.30-N-1002-01O Connection fitting, coolant vent line to cylinder head Nm 35

n Cylinder head
Number Designation ENGINE 457.9,
458.9
BA01.30-N-1003-01O Banjo bolt, coolant vent line to connection fitting Nm 35

n Cylinder head
Number Designation ENGINE 457.9,
458.9
BA01.30-N-1004-01O Compressed air line for constant throttle on cylinder head Nm 45

n Cylinder head
Number Designation ENGINE 457.9,
458.9
BA01.30-N-1005-01O Leak oil line for fuel on cylinder head Nm 15

n Engine mounts, engine supports

Number Designation ENGINE 457.9,
458.9
BA22.10-N-1006-01V Bolt, rear engine suspension lug to crankcase Nm 200

n Engine mounts, engine supports

Number Designation ENGINE 457.9,
458.9
BA22.10-N-1008-01V Bolt, clamp to rear engine suspension lug Nm 25
© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 5/7
j Engine lubrication
Number Designation Engine 457.9, Engine 457.9,
installation installation
position position
horizontal vertical, used
as bus engine
except engine
457.944/953/96
BF18.00-N-1001-01K Engine oil Filling capacity with oil Liter 32 29,5
filter
sheet BB00.40- BB00.40-
N-0228-05KOA N-0228-05KOA
sheet BB00.40- BB00.40-
N-0228-03KOA N-0228-03KOA
sheet BB00.40- BB00.40-
N-0228-01KOA N-0228-01KOA
sheet BB00.40- BB00.40-
N-0228-31KOA N-0228-31KOA
sheet BB00.40- BB00.40-
N-0228-51KOA N-0228-51KOA

j Engine lubrication
Number Designation Engine Engine 457.9,
457.944/953/96, installation
installation position
position vertical, all
vertical, used as applications
bus engine except bus
engine
BF18.00-N-1001-01K Engine oil Filling capacity with oil Liter 32 39
filter
sheet BB00.40- BB00.40-
N-0228-05KOA N-0228-05KOA
sheet BB00.40- BB00.40-
N-0228-03KOA N-0228-03KOA
sheet BB00.40- BB00.40-
N-0228-01KOA N-0228-01KOA
sheet BB00.40- BB00.40-
N-0228-31KOA N-0228-31KOA
sheet BB00.40- BB00.40-
N-0228-51KOA N-0228-51KOA

j Engine lubrication
Number Designation ENGINE 458.9 ENGINE
with rear sump 458.97/98
oil pan with except rear
firewall height sump oil pan
330 mm with firewall
height 330 mm
BF18.00-N-1001-01K Engine oil Filling capacity with oil Liter 43 29,5
filter
sheet BB00.40- BB00.40-
N-0228-05KOA N-0228-05KOA
sheet BB00.40- BB00.40-
N-0228-03KOA N-0228-03KOA
sheet BB00.40- BB00.40-
N-0228-01KOA N-0228-01KOA
sheet BB00.40- BB00.40-
N-0228-31KOA N-0228-31KOA
sheet BB00.40- BB00.40-
N-0228-51KOA N-0228-51KOA

j Engine lubrication
Number Designation ENGINE 458.99 ENGINE 458.99
with rear sump with front sump
oil pan with oil pan
firewall height
235 mm
BF18.00-N-1001-01K Engine oil Filling capacity with oil Liter 32 39
filter
sheet BB00.40- BB00.40-
N-0228-05KOA N-0228-05KOA
sheet BB00.40- BB00.40-
N-0228-03KOA N-0228-03KOA
© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 6/7
 sheet BB00.40- BB00.40-
N-0228-01KOA N-0228-01KOA
sheet BB00.40- BB00.40-
N-0228-31KOA N-0228-31KOA
sheet BB00.40- BB00.40-
N-0228-51KOA N-0228-51KOA

422 589 01 09 00

Wrench socket

Repair materials
Number Designation Order number
BR00.45-N-1028-04KOP Assembly cleaner A 000 986 56 01
BR00.45-N-1074-04KOP 3M Bristle DiscTM high-performance disc Ø 115 mm, color 3MDeutschland GmbH
white (fine), art. no.: 24539 Discrete Schurz-Strasse 1
41453 Neuss
Germany
Tel. +49 2131 14-0
Fax +49 2131 14-2649
http://www.3M.com

© Daimler Truck AG, printed: 2025-10-13, P/10/25, , AR01.30-G-5800CH 7/7