Check/face-grind cylinder head contact surfaces

AR01.30-D-7162A

Check/face-grind cylinder head contact surfaces

18.11.11

 

Remove/install



Only face cylinder head contact surface if porous or damaged points are present.

It is not necessary to rework minor variations in the flatness in the longitudinal direction. These are compensated for again when the cylinder head is tightened.

1

Remove cylinder head

Engine 602.980

AR01.30-D-5800R

Engine 602.982

AR01.30-P-5800HW

Engine 602.984/985

AR01.30-D-5800S

2

Remove valve springs and valve stem seals

AR05.30-D-3510-02A



*111589256100



*601589015900



*606589003700

3

Remove valves

4

Remove glow plugs

AR15.20-D-4111A

5.1

Remove injection nozzles (DI)

Engine 602.982

AR07.13-P-6830C

5.2

Remove nozzle holder

Engine 602.980/984/985

AR07.11-D-5500A

6

Inspect cylinder head contact surface for flatness, porous or damaged points

*BE01.30-N-1002-02D

Steel rule

7

Inspect hardness of cylinder head contact surface

 If a cylinder head has been overheated, this can result in a change in the microstructure.

Facing only produces a leaktight bond between cylinder head-cylinder head gasket-crankcase if a certain minimum hardness is achieved

AR01.30-D-7162-02A

*BE01.30-N-1008-02D

Impact hardness tester, poldi system

8

Measure height of cylinder head (inspection dimension H)

 Note measurement obtained

*BE01.30-N-1001-02D

9

Face contact surface of cylinder head

*BE01.30-N-1004-02D

 The stock removal at the cylinder head and at the crankcase together must not be more than 0.5 mm.

If the cylinder crankcase has already been remachined, the material removed on the cylinder head separation surface should not exceed a maximum of 0.3 mm.
Never machine the upper separation surface of the cylinder head, otherwise the basic bore for the camshaft bearing would be changed.

Old stock - surface grinding machine (cylinder head)

gotis://A_01_14.0

10

Once again measure height of cylinder head (inspection dimension H)

Measure stock removal.

*BE01.30-N-1001-02D

11

Measure valve setback (inspection dimension a)

AR05.30-D-4100-01A

*BE01.30-N-1006-02D

*BE01.30-N-1010-02D



*001589532100



*343589004000

12

Re-work valve seats to match stock removal at cylinder head

AR05.30-D-4511B

13

Install in the reverse order

Number

Designation

Engine 602.980/
982/983/984/985

BE01.30-N-1001-02D

Height of cylinder head (H)

New

mm

142.9 to 143.1

Wear limit after machining (stock removal max. 0.5 mm)

mm

142.4 to 142.6

See picture

AR01.30-D-7162A

BE01.30-N-1002-02D

Unevenness of contact surface

Longitudinal direction

mm

0.08

Transverse direction

mm

0.0

BE01.30-N-1004-02D

Peak-to-valley height

mm

0.004

BE01.30-N-1006-02D

Valve setback (a) with new valves and new valve seat rings

Exhaust valve

mm

0.1...0.5

Intake valve

mm

0.1...0.5

See picture

AR01.30-D-7162A

BE01.30-N-1008-02D

Hardness of cylinder head contact surface in area of sealing bead of cylinder head gasket

HB

>70

See picture

AR01.30-D-7162-02A

BE01.30-N-1010-02D

Distance from end of valve stem to base of camshaft bearing (T)

mm

20.4 to 21.4

See picture

AR05.30-D-4100-01A