Remove/install valves

AR05.30-G-3511MT

Remove/install valves

11.11.11

 

Remove/install

1

Remove cylinder head (8)

AR01.30-G-5800MT

2

Remove injection nozzle

AR07.03-G-6840MT

3

Remove needle movement sensor

Only for engine 447

AR07.04-G-0003MT

4

Measure valve setback to cylinder head contact surface

AR05.30-G-4100-01MT

*BE05.30-N-1002-01O

*BE05.30-N-1012-01O



*001589532100



*343589004000

 If the read off test value is not within the permissible tolerance machine valve seat rings or replace them:



Machine valve seat ring on intake or exhaust valve

AR05.30-G-4532-01MT

Replace valve seat ring on intake or exhaust valve

AR05.30-G-3831MT

5

Remove valve springs

Cylinder head holding fixture

AR05.30-G-3510-03MT

*BE05.30-N-1001-05G

*BE05.30-N-1002-05G



*210589004000



*442589003100

6

Pull valve stem seals (6) off valve guide

 Installation: Use new valve stem seals (6).

AR05.30-G-3510MT

7

Take out washers (4, 7) for the outer valve spring (3) and inner valve springs (5)

8

Remove exhaust valve (9) and intake valve (10) from cylinder head (8)

 Mark exhaust valves (9) and intake valves (10) relative to respective cylinder head (8).

 Installation: Oil valve stems with engine oil. Observe identification of exhaust valves (9) and intake valves (10).



Checking

9

Check valve guides for wear

AR05.30-G-3731MT

10

Perform visual inspection on valve seat rings

 Valve seats must not be burnt. If the valve seat is slightly stamped in then follow-up operations can take place without replacing valve seat ring.

The damaged valve seat ring must be replaced in all other cases:



Replace valve seat rings

AR05.30-G-3831MT

11

Perform visual inspection on exhaust (9) and intake valves (10)



 The valve stem ends must not have any surface damage.

 Valve keyways must not be worn out and the chrome layer on the valve stems must be complete.

 In case of complaint: replace exhaust valve (9) or intake valve (10).

12

Check exhaust valves (9) and intake valve (10) for wear, smooth operation and dimensional accuracy

 Grind or replace exhaust valves (9) or intake valves (10) if necessary.

Straightening exhaust valves (9) or intake valves (10) is not permissible.

AR05.30-G-4202-01MT

*BE05.30-N-1003-01O

*BE05.30-N-1004-01O

*BE05.30-N-1005-01O

*BE05.30-N-1006-01O

*BE05.30-N-1007-01O

*BE05.30-N-1008-01O

*BE05.30-N-1009-01O

*BE05.30-N-1010-01O

13

Install in the reverse order

14

Measure valve setback to cylinder head contact surface

 After installing, measure valve setback and permissible difference between both valves on machined valves again.

AR05.30-G-4100-01MT

Number

Designation

Engine
447.903

BE05.30-N-1002-01O

Valve setback relative to cylinder head contact surface

mm

0.7 to 1.1

BE05.30-N-1003-01O

Valve seat angle "A"

Inlet

°

30

Outlet

°

45

See picture

AR05.30-G-4202-01MT

BE05.30-N-1004-01O

Valve disk dia. "B"

Inlet

mm

58.8 to 59.0

Outlet

mm

50.9 to 51.1

See picture

-

BE05.30-N-1005-01O

Valve seat width at valve disk "F"

New

Inlet

mm

4.5 to 5.5

Outlet

mm

4.5 to 5.5

Machining limit

Inlet

mm

6.50

Outlet

mm

6.50

See picture

AR05.30-G-4202-01MT

BE05.30-N-1006-01O

Valve length "C"

Inlet

mm

142.3...142.7

Outlet

mm

142.3...142.7

See picture

AR05.30-G-4202-01MT

BE05.30-N-1007-01O

Valve stem dia. "E"

Inlet

mm

11.932 to 11.950

Outlet

mm

11.922 to 11.940

See picture

AR05.30-G-4202-01MT

BE05.30-N-1008-01O

Hardness of valve stem on shaft end

HRC

54 to 60

BE05.30-N-1009-01O

Intake valve seat face machining dimension "H" relative to valve seat face diameter "G"

Dim. "G"

mm

54.99 to 55.01

New

Dim. "H"

mm

3.6 to 3.8

Machining limit

Dim. "H"

mm

3.3

See picture

AR05.30-G-4202-01MT

BE05.30-N-1010-01O

Exhaust valve seat face machining dimension "H" relative to valve seat face diameter "G"

Dim. "G"

mm

47.99 to 48.01

New

Dim. "H"

mm

3.0 to 3.2

Machining limit

Dim. "H"

mm

2.7

See picture

AR05.30-G-4202-01MT

BE05.30-N-1012-01O

Permissible difference between valve setback to cylinder head separating surface

Inlet

mm

0.2

Outlet

mm

0.2

Number

Designation

Engine
444.901

BE05.30-N-1002-01O

Valve setback relative to cylinder head contact surface

mm

0.7 to 1.1

BE05.30-N-1003-01O

Valve seat angle "A"

Inlet

°

30

Outlet

°

45

See picture

AR05.30-G-4202-01MT

BE05.30-N-1004-01O

Valve disk dia. "B"

Inlet

mm

58.8 to 59.0

Outlet

mm

50.9 to 51.1

See picture

-

BE05.30-N-1005-01O

Valve seat width at valve disk "F"

New

Inlet

mm

4.5 to 5.5

Outlet

mm

4.5 to 5.5

Machining limit

Inlet

mm

6.50

Outlet

mm

6.50

See picture

AR05.30-G-4202-01MT

BE05.30-N-1006-01O

Valve length "C"

Inlet

mm

142.3...142.7

Outlet

mm

142.3...142.7

See picture

AR05.30-G-4202-01MT

BE05.30-N-1007-01O

Valve stem dia. "E"

Inlet

mm

11.932 to 11.950

Outlet

mm

11.922 to 11.940

See picture

AR05.30-G-4202-01MT

BE05.30-N-1008-01O

Hardness of valve stem on shaft end

HRC

54 to 60

BE05.30-N-1009-01O

Intake valve seat face machining dimension "H" relative to valve seat face diameter "G"

Dim. "G"

mm

54.99 to 55.01

New

Dim. "H"

mm

3.6 to 3.8

Machining limit

Dim. "H"

mm

3.3

See picture

AR05.30-G-4202-01MT

BE05.30-N-1010-01O

Exhaust valve seat face machining dimension "H" relative to valve seat face diameter "G"

Dim. "G"

mm

47.99 to 48.01

New

Dim. "H"

mm

3.0 to 3.2

Machining limit

Dim. "H"

mm

2.7

See picture

AR05.30-G-4202-01MT

BE05.30-N-1012-01O

Permissible difference between valve setback to cylinder head separating surface

Inlet

mm

0.2

Outlet

mm

0.2

Number

Designation

Engine 444.901,
447.903

BE05.30-N-1001-05G

Length of valve spring, outside (no load)

mm

67.5 to 68.5

BE05.30-N-1002-05G

Length of valve spring, inside (no load)

mm

69.5 to 70.5