Check, remove/install valve guides

AR05.30-I-3731B

Check, remove/install valve guides

23.5.13

ENGINE

904.941 in MODEL 684.482

1

Valve guide

2

Cylinder head

A

Bore dia. (in cylinder head)

A1

Outside dia. (valve guide)

B

Inside dia. (valve guide)

C

Length (valve guide)

D

Protrusion (valve guide)

1

Valve guide

4

Staged drift

7

Reamer (adjustable)

2

Cylinder head

5

Reamer (adjustable)

8

Reamer

3

Drift

6

Sleeve



Remove

1

Remove valves

AR05.30-I-3511B

2

Remove valve stem seals

AR05.30-I-3510B

3

Remove supporting discs for valve springs.

Check

4

Check valve guides (1) for surface damage

If a valve guide (1) has surface damage:



Mark the corresponding valve guide (1).

5

Check valve guides (1) inside dia. (B) using a drift (3)

 Drift

*102589002300

If it is possible to insert side of drift (3) marked with "+" into valve guide (1):



Mark the corresponding valve guide (1).

If in this and the previous operation step no damaged valve guides (1) were established:



Continue with operation step 14



Remove

6

Remove marked, damaged valve guides (1) from the combustion side out of the cylinder head (2)

 Staged drift

*103589031500

Check

7

Check respective bore dia. (A) in cylinder head (2)

Bore dia. in cylinder head

*BE05.30-N-1002-02B

If one or more bore diameters (A) deviate from the prescribed values:



Ream out respective hole to the next deviation or replace cylinder head (2).

 The reamer (5) must only be turned clockwise.

 Note overlap of valve guide (1) with respect to cylinder head (2).

Overlap in cylinder head

*BE05.30-N-1005-02B

Outside dia.

*BE05.30-N-1001-02B

 Reamer

*000589185300



Install

 Danger !

Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.

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

AS00.00-Z-0003-01A

8

Place new valve guides (1) in the supercooling box and pour in liquid nitrogen

 If bore in cylinder head (2) has been machined, use valve guide (1) with an appropriate deviation.

 Supercool the valve guides (1) for about 20 to 30 min.

 Supercooler box

*346589006300

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

9

Heat cylinder head (2) in water bath

 Temperature approx. 80°C.

 Danger !

Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.

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

AS00.00-Z-0003-01A

10

Using pliers, take out valve guides (1) from the cooling box and press into the heated cylinder head (2) using the punch-in drift and the sleeve (6)

 The protrusion (D) for the intake or exhaust valve is dependent on the installation position of the sleeve (6). Note marking on the sleeve (6).

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

*BE05.30-N-1007-02B

 Sleeve

*904589086300

 Drift punch

*904589011500

11

Ream out new valve guides (1)

 The reamers (7, 8) must only be turned clockwise. First ream out using the adjustable reamer (7) to a diameter of 7.95 mm then ream out with the reamer (8) to the prescribed inside diameter.

Inside dia. (machined dimension)

*BE05.30-N-1003-02B

 Reamer

*000589215300

12

Clean new valve guides (1) with a cleaning brush



Check

13

Check valve guides inside dia. (B) using a drift (3)

 Repeat operation steps 11 to 13 if necessary or replace valve guide (1).

 Drift

*102589002300



Install

14

Install supporting discs for valve springs.

15

Install valve stem seals.

AR05.30-I-3510B

16

Install valves

AR05.30-I-3511B

Test values for valve guides

Number

Designation

Engine 904.941 in model 684

BE05.30-N-1002-02B

Bore dia. in cylinder head

Default

mm

14,000...14,018

Oversize 0.2

mm

14,200...14,218

Deviation 0.5

mm

–

Test values for valve guides

Number

Designation

Engine 904.941 in model 684

BE05.30-N-1001-02B

Outside dia.

Default

mm

14,028...14,046

Oversize 0.2

mm

14,228...14,246

Deviation 0.5

mm

–

Test values for valve guides

Number

Designation

Engine 904.941 in model 684

BE05.30-N-1005-02B

Overlap in cylinder head

mm

0,010...0,046

Test values for valve guides

Number

Designation

Engine 904.941 in model 684

BE05.30-N-1007-02B

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

Inlet

mm

13,7...14,5

Outlet

mm

17,2...18,0

Test values for valve guides

Number

Designation

Engine 904.941 in model 684

BE05.30-N-1003-02B

Inside dia. (machined dimension)

mm

8,000...8,022