Check/face-grind cylinder head contact surfaces

AR01.30-W-7162B

Check/face-grind cylinder head contact surfaces

13.9.06

15.7.06

 Dial indicator holder - added.

Step 5

*541589004000



Removing

1

Remove cylinder head (1)

AR01.30-W-5800B

2

Remove nozzle holder combination

AR07.03-W-6831B

3

Clean cylinder head (1)

 Only clean cylinder head sealing surface by scraping.



Check

4

Measure height (H) of cylinder head

 Install new cylinder head (1) with inductive hardening if necessary.

*BE01.30-N-1001-02C

5

Measure valve setback (B) at both intake valves (2) and at exhaust valve (3) and note.

AR05.30-W-4100-01B

*BE05.30-N-1001-01C



*001589532100



*541589004000

 Of the read off test value before or after possible face machining is not within permissible tolerances, install new cylinder head (1) with inductive hardening.

6

Measure setback of constant throttle valve (M) to cylinder head contact surface

 If measurement differs from specification:



*BE01.50-N-1007-01A

- For cylinder head (1) with valve seat ring for constant throttle, install new cylinder head (1) with inductive hardening.

- For a cylinder head (1) without valve seat ring for constant throttle, install valve seat ring for constant throttle.

AR01.50-W-0002A

7

Inspect flatness of cylinder head contact surface (combustion chamber side)

*BE01.30-N-1002-02C

Machining

8

Remove intake valves (2) and exhaust valves (3)

 If intake valves (2) and exhaust valves (3) are used again, mark installation location relative to intake valves (2) and exhaust valves (3).

AR05.30-W-3511B

9

Remove constant throttle valve (4)

AR01.50-W-1000B

10

Machine cylinder head contact surface (on the combustion chamber side) by face grinding it flat

The height of the cylinder head (H) must not be less than smallest permissible height after stock removal.

*BE01.30-N-1001-02C

The surface quality of the cylinder head contact surface must be maintained.

*BE01.30-N-1003-02C

11

Clean cylinder head (1)

 No dirt should find its way into the bores for engine oil, coolant, push rods and cylinder head bolts otherwise engine damage can occur.



Install

12

Install intake valves (2) and exhaust valves (3)

 Observe identification of intake valves (2) and exhaust valves (3).

AR05.30-W-3511B

13

Measure valve setback (B) at both inlet valves (2) and at exhaust valves (3).

 Install new cylinder head (1) with inductive hardening if necessary.

AR05.30-W-4100-01B

*BE05.30-N-1001-01C



*001589532100



*541589004000

14

Install constant throttle (4)

AR01.50-W-1000B

15

Install nozzle holder combination

AR07.03-W-6831B

16

Install cylinder head (1)

AR01.30-W-5800B

Number

Designation

Engine
541.9, 542.9
without inductive hardening at cylinder head

BE01.30-N-1001-02C

Height of cylinder head

when new

mm

113.85 to 114.15

after stock removal

mm

113.5

BE01.30-N-1002-02C

Permissible variation of flatness of lower separating surface

Rate of wear and tear

mm

0.1

BE01.30-N-1003-02C

Surface finish of cylinder head separating surface

Peak-to-valley height Rz

μm

8

Wave depth Wt

μm

10

Number

Designation

Engine
541.9, 542.9

BE01.50-N-1007-01A

Setback of constant throttle valve relative to cylinder head separating surface

mm

4.6 to 5.4

Number

Designation

Engine 541.9, 542.9

BE05.30-N-1001-01C

Valve setback to cylinder head
contact surface

mm

0.70 to 1.05