Remove/install valves

AR05.30-G-3511DD

Remove/install valves

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

Inlet valves

5

Dial indicator holder

2

Outlet valve

J

Difference between both inlet valve stem ends

3

Cylinder head

K

Valve setback relative to cylinder head contact surface

4

Mount dial indicator

2

Outlet valve

3

Cylinder head

6

Valve guides

7

Valve stem seal

8

Valve spring

9

Valve spring retainer

10

Conical valve keepers

11

Drift

12

Cylinder brush

 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

 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/install

1.1

Remove nozzle holder assembly.

With natural gas engine

AR07.03-G-6831DD

1.2

Remove spark plugs.

With diesel engine

AR15.12-G-1010DE

2

Remove cylinder head (3).

Natural gas engine

AR01.30-G-5800DE

Diesel engine

AR01.30-G-5800DD

3

Measure and note valve setback to cylinder head contact surface (K) and difference between both intake valve stem ends (J).

AR05.30-G-4100-01DD

Valve setback relative to cylinder head contact surface

*BE05.30-N-1001-01K

Permissible difference of intake valves measured between cylinder head and valve stem end

*BE05.30-N-1014-01K

 Dial gage

*001589532100

 Dial indicator holder

*343589004000

 Dial indicator holder

*363589022100

 Extension

*366589002105

If there is a deviation from specified values:



Replace cylinder head (3).

4

Remove valve springs (8) and valve stem seals (7).

AR05.30-G-3510-02DD



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

BT05.30-N-0004-01RH

 Magnetic pin

*210589004000

 Valve tool case

*541589006100

 Pliers

*606589003700

5

Mark intake valves (1) and exhaust valve (2) relative to cylinder head (3).

6

Remove intake valves (1) and exhaust valve (2) from cylinder head (3).

7

Clean valve guides (6) using cylinder brush (12).

 Cylinder brush

*000589106800



Check

8

Check inside diameter of the valve guides (6) with drift (11) for wear.

Inside diameter (machined dimension)

*BE05.30-N-1003-02J

 Drift

*102589002300

If the side of the drift (11) marked with "+" can be inserted into valve guide (6):



Replace corresponding valve guide (6).

AR05.30-G-3731DD

9

Check valve seat rings in cylinder head (3).

If the valve seat rings are damaged:



Replace cylinder head (3).

10

Check intake valves (1) for further applicability.

 The valve stems must have no surface damage.
The grooves for the conical valve keepers (10) must not be worn out.
The valve seats must not be burnt.

If there is surface damage on the valve stems:



Replace respective intake valve (1).

11

Check exhaust valve (2) for further applicability.

 The valve stems must have no surface damage.
The grooves for the conical valve keepers (10) must not be worn out.
The valve seats must not be burnt.

If there is surface damage on the valve stems:



Replace respective exhaust valve (2).

12

Install in the reverse order

Check values for valves

Number

Designation

Engine 900.9 (except 900.910), 902.9 (except 902.910/919), 924.9, 925.9, 926.9 in model 000.001

Engine 900.910, engine 902.910/919

BE05.30-N-1001-01K

Valve setback relative to cylinder head contact surface

Inlet

mm

1,1...1,5

1,1...1,5

Outlet

mm

1,1...1,5

1,1...1,5

Check values for valves

Number

Designation

ENGINE 906.901/902

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

BE05.30-N-1001-01K

Valve setback relative to cylinder head contact surface

Inlet

mm

1,1...1,5

1,1...1,5

Outlet

mm

1,3...1,7

1,1...1,5

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## (except 906.901/902) ## as of 041956

BE05.30-N-1001-01K

Valve setback relative to cylinder head contact surface

Inlet

mm

1,1...1,5

Outlet

mm

1,1...1,5

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 valves

Number

Designation

Engine 900.9 (except 900.910), 902.9 (except 902.910/919), 924.9, 925.9, 926.9 in model 000.001

Engine 900.910, engine 902.910/919

BE05.30-N-1014-01K

Permissible difference of intake valves measured between cylinder head and valve stem end

mm

0,3

0,3

Check values for valves

Number

Designation

ENGINE 906.901/902

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

BE05.30-N-1014-01K

Permissible difference of intake valves measured between cylinder head and valve stem end

mm

0,3

0,3

Check values for valves

Number

Designation

ENGINE 904.9## ## as of 039740, ENGINE 906.9## (except 906.901/902) ## as of 041956

BE05.30-N-1014-01K

Permissible difference of intake valves measured between cylinder head and valve stem end

mm

0,3