Check, remove/install valve guides

AR05.30-G-3731DD

Check, remove/install valve guides

14.08.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Modification notes

19.03.2019

Document completely revised.

1

Valve guide

2

Cylinder head

3

Cylinder brush

4

Base washer

A

Bore diameter in cylinder head (2)

B

Inside diameter

D

Protrusion

1

Valve guide

8

Punch-in drift

2

Cylinder head

9

Sleeve

5

Drift

10

Adjustable reamer

6

Staged drift

11

Reamer

7

Reamer

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Warning

Risk of injury when handling solid carbon dioxide (dry ice) caused by touching extremely cold objects or by inhaling gaseous carbon dioxide

Wear heat protective gloves, protective clothing and full eye protection. Ensure that the work area is adequately ventilated.

AS00.00-Z-0029-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A



Remove

1.1

Remove nozzle holder assembly.

With diesel engine

AR07.03-G-6831DD

1.2

Remove spark plugs.

For a natural gas engine

AR15.12-G-1010DE

2

Remove cylinder head (2).

Diesel engine

AR01.30-G-5800DD

Natural gas engine

AR01.30-G-5800DE

3

Remove valves.

AR05.30-G-3511DD



Exhaust valve spring, exhaust valve and exhaust valve seat ring modified

BT05.30-N-0004-01RH

4

Remove support disks (4).

5

Clean valve guides (1) using cylinder brush (3).

 Cylinder brush

*000589106800



Check

6

Check the inside diameter (B) of the valve guides (1) with a drift (5).

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Inside diameter (machined dimension)

*BE05.30-N-1003-02J

 Drift

*102589002300

If the side of the drift (5) marked with "+" can be inserted into valve guide (1),



Replace corresponding valve guide (1).

7

Set down cylinder head (2) on suitable wooden block.

 The combustion end of cylinder head (2) must face upward.

8

Knock worn valve guides (1) out of the cylinder head (2) from the combustion end using the staged drift (6).

 Staged drift

*103589031500

9

Measure valve guides (1) and bores in the cylinder head (2).

AR05.30-G-3731-09DD

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Outside diameter

*BE05.30-N-1001-02J

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Bore diameter in cylinder head

*BE05.30-N-1002-02J

 Dial gage

*001589532100

 Cylinder brush

*000589106800



Install

10

Turn cylinder head (2) and set down on suitable wooden block.

 The combustion end of the cylinder head (2) must face downward.

11

Ream bores for the valve guides (1) in the cylinder head (2) to the next largest deviation using a corresponding reamer (7).

Only if the valve guides (1) are to be installed at the next deviation.

 Observe deviations of the bore diameter in the cylinder head (2).

 In the event of a deviation of 0.2 mm, use the reamer (7) with a diameter of 14.2 mm H7 and in the event of a deviation of 0.5 mm, use the reamer (7) with a diameter of 14.5 mm H7.
Only turn reamer (7) clockwise.

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Bore diameter in cylinder head

*BE05.30-N-1002-02J

12

Allocate new valve guides (1) to the bores in the cylinder head (2) and mark.

13

Pour solid carbon dioxide (dry ice) into the cooling box and insert new valve guides (1) with pliers.

 The valve guides (1) must be completely covered by the solid carbon dioxide (dry ice). Supercool valve guides (1) for approx. 20 to 30 min.

 Supercooler box

*346589006300

14

Take valve guide (1) out of the cooling box using pliers, push sleeve (9) over the valve guide (1), and knock valve guide (1) into the cylinder head (2) using the punch-in drift (8).

 Observe the markings on the valve guides (1) and their assignments to the bores in cylinder head (2).
The protrusion (D) of valve guide (1) from the contact surface to the top edge of valve guide (1) is specified according to the installation position and length of sleeve (9).

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Overlap in cylinder head

*BE05.30-N-1005-02J

Protrusion of valve guide from contact surface at top edge of valve guide

*BE05.30-N-1007-02J

 Sleeve

*904589086300

 Drift punch

*904589011500

15

Remove punch-in drift (8) and sleeve (9).

16

Ream bore in valve guide (1) in stages using adjustable reamer (10) until the reamer (11) can be set at the bore in valve guide (1).

 Use adjustable reamer (10) with a diameter of 7.2 to 8.0 mm. Only turn adjustable reamer (10) clockwise.

 Reamer

*000589215300

17

Ream bore in the valve guide (1) to the inside diameter (B) using the reamer (11).

 Only  turn reamer (11) clockwise.

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001Inside diameter (machined dimension)

*BE05.30-N-1003-02J

 Reamer

*000589215300

18

Clean valve guides (1) using cylinder brush (3).

 Cylinder brush

*000589106800

19

Lubricate valve stems of the valves with engine oil and push valves into the valve guides (1) for testing.

 If used valves are being reinstalled, the markings made on cylinder head (2) and on the valves must be observed. The valve stems must make smooth contact all round the inside of the valve guides (1).

20

Insert support disks (4).

21

Install valves.

AR05.30-G-3511DD



Exhaust valve spring, exhaust valve and exhaust valve seat ring modified

BT05.30-N-0004-01RH

22

Install cylinder head (2).

Diesel engine

AR01.30-G-5800DD

Natural gas engine

AR01.30-G-5800DE

23.1

Install nozzle holder assembly.

With diesel engine

AR07.03-G-6831DD

23.2

Install spark plugs.

For a natural gas engine

AR15.12-G-1010DE

Check values for valve guides

Number

Designation

ENGINE 900.9, 902.9

ENGINE 904.9## (except 904.971) ## up to 039739, 924.9## ## up to 039739, ENGINE 906.9## (except 906.901/902) ## up to 041955

BE05.30-N-1001-02J

Outside diameter

Default

mm

14,028...14,046

13,028...13,046

Oversize 0.2

mm

14,228...14,246

13,228...13,246

Deviation 0.5

mm

–

–

Check values for valve guides

Number

Designation

ENGINE 904.9, 924.9## ## as of 039740, ENGINE 906.9## ## as of 041956, ENGINE 906.901/902 ## up to 041955

Engine 925.9 in model 000.001

BE05.30-N-1001-02J

Outside diameter

Default

mm

14,028...14,046

14,028...14,046

Oversize 0.2

mm

14,228...14,246

14,228...14,246

Deviation 0.5

mm

–

14,528...14,546

Check values for valve guides

Number

Designation

ENGINE 926.9## ## up to 041955

ENGINE 926.9## ## as of 041956

BE05.30-N-1001-02J

Outside diameter

Default

mm

13,028...13,046

14,028...14,046

Oversize 0.2

mm

13,228...13,246

14,228...14,246

Deviation 0.5

mm

–

14,528...14,546

Check values for valve guides

Number

Designation

ENGINE 900.9, 902.9

ENGINE 904.9## (except 904.971) ## up to 039739, 924.9## ## up to 039739, ENGINE 906.9## (except 906.901/902) ## up to 041955

BE05.30-N-1002-02J

Bore diameter in cylinder head

Default

mm

14,000...14,018

13,000...13,018

Oversize 0.2

mm

14,200...14,218

13,200...13,218

Deviation 0.5

mm

–

–

Check values for valve guides

Number

Designation

ENGINE 904.9, 924.9## ## as of 039740, ENGINE 906.9## ## as of 041956, ENGINE 906.901/902 ## up to 041955

Engine 925.9 in model 000.001

BE05.30-N-1002-02J

Bore diameter in cylinder head

Default

mm

14,000...14,018

14,000...14,018

Oversize 0.2

mm

14,200...14,218

14,200...14,218

Deviation 0.5

mm

–

14,500...14,518

Check values for valve guides

Number

Designation

ENGINE 926.9## ## up to 041955

ENGINE 926.9## ## as of 041956

BE05.30-N-1002-02J

Bore diameter in cylinder head

Default

mm

13,000...13,018

14,000...14,018

Oversize 0.2

mm

13,200...13,218

14,200...14,218

Deviation 0.5

mm

–

–

Check values for valve guides

Number

Designation

ENGINE 900.9, 902.9

ENGINE 904.9## (except 904.971) ## up to 039739, 924.9## ## up to 039739, ENGINE 906.9## (except 906.901/902) ## up to 041955

BE05.30-N-1003-02J

Inside diameter (machined dimension)

mm

8,000...8,022

8,000...8,022

Check values for valve guides

Number

Designation

ENGINE 904.9, 924.9## ## as of 039740, ENGINE 906.9## ## as of 041956, ENGINE 906.901/902 ## up to 041955

Engine 925.9 in model 000.001

BE05.30-N-1003-02J

Inside diameter (machined dimension)

mm

8,000...8,022

8,000...8,022

Check values for valve guides

Number

Designation

ENGINE 926.9## ## up to 041955

ENGINE 926.9## ## as of 041956

BE05.30-N-1003-02J

Inside diameter (machined dimension)

mm

8,000...8,022

8,000...8,022

Check values for valve guides

Number

Designation

ENGINE 900.9, 902.9

ENGINE 904.9## (except 904.971) ## up to 039739, 924.9## ## up to 039739, ENGINE 906.9## (except 906.901/902) ## up to 041955

BE05.30-N-1005-02J

Overlap in cylinder head

mm

0,010...0,046

0,010...0,046

Check values for valve guides

Number

Designation

ENGINE 904.9, 924.9## ## as of 039740, ENGINE 906.9## ## as of 041956, ENGINE 906.901/902 ## up to 041955

Engine 925.9 in model 000.001

BE05.30-N-1005-02J

Overlap in cylinder head

mm

0,010...0,046

0,010...0,046

Check values for valve guides

Number

Designation

ENGINE 926.9## ## up to 041955

ENGINE 926.9## ## as of 041956

BE05.30-N-1005-02J

Overlap in cylinder head

mm

0,010...0,046

0,010...0,046

Check values for valve guides

Number

Designation

ENGINE 900.9, 902.9

ENGINE 904.9## (except 904.971) ## up to 039739, 924.9## ## up to 039739, ENGINE 906.9## (except 906.901/902) ## up to 041955

BE05.30-N-1007-02J

Protrusion of valve guide from contact surface at top edge of valve guide

Inlet

mm

13,7...14,5

14,1...14,5

Outlet

mm

17,2...18,0

17,6...18,0

Check values for valve guides

Number

Designation

ENGINE 904.9, 924.9## ## as of 039740, ENGINE 906.9## ## as of 041956, ENGINE 906.901/902 ## up to 041955

Engine 925.9 in model 000.001

BE05.30-N-1007-02J

Protrusion of valve guide from contact surface at top edge of valve guide

Inlet

mm

13,7...14,5

13,7...14,5

Outlet

mm

17,2...18,0

17,2...18,0

Check values for valve guides

Number

Designation

ENGINE 926.9## ## up to 041955

ENGINE 926.9## ## as of 041956

BE05.30-N-1007-02J

Protrusion of valve guide from contact surface at top edge of valve guide

Inlet

mm

14,1...14,5

13,7...14,5

Outlet

mm

17,6...18,0

17,2...18,0