AR05.30-B-3731TC | Check, remove/install valve guides | 12.02.16 |
Cumbustion engine 457.9 with Vehicle 958.4
Cumbustion engine 460.984 with Vehicle 934.### #R, 934.### #S
W05.30-1125-06
1 Engine head
2 valve guide
3 Mandrel
4 Cylindrical brush
5 Support washer
6 Staggered punch
B Inside diameter
W05.30-1088-09
1 Engine head
2 valve guide
7 Reamer
8 Mandrel
9 Sleeve
10 Reamer (adjustable)
11 Reamer
A Bore diameter on the head
B Inside diameter
D Distance
| Remove | ||
1 | Disassemble the combined injector holder | ||
2 | Remove the head (1) | ||
3 | Remove the valves | ||
4 | Remove the support washers (5) | ||
5 | Clean the valve guides (2) using the cylindrical brush (4) | | |
| Inspect | ||
6 | Using the mandrel (3), inspect the inside diameters (B) of the valve guides (2) | ||
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If the mandrel (3) side marked with "+" on the valve guide (2) can be inserted, replace the respective valve guide (2). | |||
7 | Place the head (1) on appropriate wooden shims | The combustion side on the cylinder head (1) should be pointing upwards. | |
8 | Knock the worn valve guides (2) off the head (1) using a staggered punch (6) from the combustion side | | |
9 | Measure the valve guides (2) and the holes in the cylinder head (1) | ||
Cylindrical brush | |||
Dial indicator | |||
| Installing | ||
10 | Rotate the head (1) and place it on suitable wooden shims | The combustion side on the cylinder head (1) should be pointing downwards. | |
11 | Ream the holes for the valve guides (2) on the head (1), using a reamer corresponding to the next higher tolerance deviation | Only when the valve guides (2) are installed with the next largest tolerance deviation. | |
Note the tolerance deviations of the hole diameters in the head (A). | |||
For the 0.2 mm tolerance deviation, use the reamer (7) with Ú 15.2 mm H7 and, for the 0.4 mm tolerance deviation, use the reamer (7) with Ú 15.4 mm H7. Rotate the reamer (7) only clockwise. | |||
12 | Match and identify the new valve guides (2) on the cylinder head (1) holes | Match only the modified valve guides (2). | |
| Valve stem and valve guide seals changed | From engine final number 891212 | |
Danger! | Risk of injury when handling with solid carbon dioxide (dry ice), when touching opposite objects strongly cooled, or by carbon dioxide gas inhalation | Wear thermal gloves, protective clothing and goggles. Provide adequate ventilation. | |
13 | Fill the cooling box with solid carbon dioxide (dry ice), using pliers, and place the new valve guides (2) | The valve guides (2) must be fully covered with carbon dioxide (dry ice). Cool the valve guides (2) for approximately 20 to 30 minutes. | |
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Danger! | Risk of injury when handling with solid carbon dioxide (dry ice), when touching opposite objects strongly cooled, or by carbon dioxide gas inhalation | Wear thermal gloves, protective clothing and goggles. Provide adequate ventilation. | |
14 | Remove the valve guides (2) from inside the cooling box using pliers, insert the sleeve (9) on the valve guide (2) and, with a spiking punch (8), tap the valve guide (2) to insert it in the cylinder head (1) | Note matching and identification of the valve guides (2) for the holes in the head (1). | |
Based on the installation position and the length of the respective sleeve (9), the protrusion (D) of the upper edge of the valve guide (2) to the valve spring bearing surface will be provided. | |||
Valve guide cap on the cylinder head | |||
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15 | Remove the staggered punch (8) and the sleeve (9) | ||
16 | Using the adjustable reamer (10), gradually ream the hole on the valve guide (2) until the reamer (11) can be seated on the valve guide (2) | Use adjustable reamers (10) with Ú 8.4 to 9.0 mm. Rotate the reamer (10) only clockwise. | |
17 | Enlarge the hole in the valve guide (2) using the reamer (11) in the bore (B) | Rotate the reamer (11) only clockwise. | |
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18 | Clean the valve guides (2) using the cylindrical brush (4) | | |
19 | Lubricate the valve stems with motor oil and, for testing purposes, insert the valves in the valve guides (2) | If used valves are installed again, the markings placed on both the head (1) and valves should be observed. The valve stems should slide sucking on the valve guides (2). | |
20 | Insert the support washers (5) | ||
21 | Install the valves | ||
22 | Install the head (1) | ||
23 | Install the combined injector holder |
Test values for valve guides
Número | Denominação | Engine 457.9; 460.984 | |||
BE05.30-B-1001-02B | Valve guide external diameter | Normal | mm | 15.028...15.046 | |
Repair I | mm | 15.228...15.246 | |||
repair II | mm | 15.428...15.446 | |||
BE05.30-B-1002-02B | Valve guide housing diameter on the head | Normal | mm | 15.000...15.018 | |
Repair I | mm | 15.200...15.218 | |||
repair II | mm | 15.400...15.418 | |||
BE05.30-B-1003-02B | Valve guide internal diameter (final finishing) | Normal | mm | 9.000...9.022 | |
wear limit | mm | 9.050 | |||
BE05.30-B-1005-02B | Valve guide mounting height on the head | Intake | mm | 19.65...20.95 | |
Exhaust | mm | 19.65...20.95 | |||
BE05.30-B-1007-02B | Covering in the head | mm | 0.010...0.046 | ||
000 589 10 53 00
Reamer
000 589 10 68 00
Cylindrical brush
001 589 53 21 00
Measuring dial
103 589 02 15 00
Staggered mandrel
117 589 03 23 00
Mandrel
346 589 00 63 00
Cooling box
541 589 00 43 00
Punch with sleeve