Check, remove/install valve guides

AR05.30-D-3731AD

Check, remove/install valve guides

7.7.08



Removing

1

Remove nozzle holder combination

AR07.03-D-6831AD

2

Remove cylinder head (2)

AR01.30-D-5800AD

3

Remove valves

AR05.30-D-3511AD

4

Take out support disks (4)

5

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



*000589106800



Check

6

Check the inside diameter (B) of valve guides (1) using drift (5)

 If the side marked "+" of drift (5) can be inserted into valve guides (1), the respective valve guides (1) must be replaced.

Inside diameter (B) (machining dimension)

*BE05.30-N-1003-02B



*102589002300

7

Lay cylinder head (2) on a suitable wooden block

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

8

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



*103589031500

9

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

AR05.30-D-3731-09AD

Outside diameter

*BE05.30-N-1001-02B

Bore hole diameter in the cylinder head (A)

*BE05.30-N-1002-02B



*000589106800



*001589532100



Install

10

Turn the cylinder head (2) and place it on suitable support blocks

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

11

Ream the valve guide bores (1) in the cylinder head (2) to the next deviation using a suitable reamer (7)

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

Note the deviation of the bore diameter in cylinder head (A).

*BE05.30-N-1002-02B

 For a deviation of 0.2 mm use a reamer (7) with a dia. of 14.2 mm H7 and for a deviation of 0.5 mm use a reamer (7) a dia. of 14.5 mm H7 . Only turn reamer (7) clockwise.

12

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

 Danger!

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

13

Pour solid carbon dioxide (dry ice) into the cooling box, and insert new valve guides (1) using tongs

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



*346589006300

 Danger!

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

14

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

 Observe the markings on the valve guides (1) and their assignments to the bores in cylinder head (2).

Valve guide overlap in cylinder head

*BE05.30-N-1005-02B

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).

*BE05.30-N-1007-02B



*904589011500



*904589086300

15

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

16

Ream out bores in valve guides (1) using a reamer (adjustable) (10) in stages until reamer (11) can be placed in the bores in valve guides (1)

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

17

Ream the bores in valve guides (1) to inside diameter (B) using reamer (11)

 Only turn reamer (11) clockwise.

Inside diameter (B) (machining dimension)

*BE05.30-N-1003-02B



*000589215300

18

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



*000589106800

19

To test them, lubricate the valve stems with engine oil and push the valves into valve guides (1)

 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-D-3511AD

22

Install cylinder head (2)

AR01.30-D-5800AD

23

Install nozzle holder combination

AR07.03-D-6831AD

Number

Designation

Engine
900.9

BE05.30-N-1001-02B

Outside dia.

Default

mm

14.028 to 14.046

Deviation 0.2

mm

14.228 to 14.246

Deviation 0.5

mm

14.528 to 14.546

BE05.30-N-1002-02B

Bore dia. in cylinder head

Default

mm

14.000 to 14.018

Deviation 0.2

mm

14.200 to 14.218

Deviation 0.5

mm

14.500 to 14.518

BE05.30-N-1003-02B

Inside dia. (machined dimension)

mm

8.000 to 8.022

BE05.30-N-1005-02B

Overlap in cylinder head

mm

0.010...0.046

BE05.30-N-1007-02B

Protrusion of valve guide from surface to upper edge of valve guide

Inlet

mm

13.7 to 14.5

Outlet

mm

17.2 to 18.0