Remove/install valves

AR05.30-I-3511B

Remove/install valves

23.5.13

ENGINE

904.941 in MODEL 684.482

1

Valve lock

2

Valve spring retainer

3

Valve spring (intake valve)

4

Valve spring (exhaust valve)

5

Cylinder head

6

Intake valve

7

Exhaust valve

8

Valve lifter with extra piece

9

Valve stem seal

12.1

Base plate

12.2

Assembly cartridge

12.3

Thrust fork

12.4

Retaining fork

5

Cylinder head

6

Intake valve

7

Exhaust valve

10

Mount dial indicator

11

Dial indicator holder

A

Valve seat angle

B

Valve disk dia.

C2

Valve length

E

Valve stem dia.

F

Valve seat width on the valve disk

G

Valve seat faces dia.

H

Valve seat faces machining dimension related to valve seat faces dia.

 

Remove/install

1

Remove cylinder head (5)

AR01.30-I-5800B

2

Remove nozzle holder combinations

AR07.03-I-6831B

3

Check valve setback of intake and exhaust valves (6, 7)

AR05.30-I-4100-01B

 Installation: If intake or exhaust valves (6, 7) are machined or replaced or the cylinder head was replaced; measure the valve setback again.

Valve setback relative to cylinder head contact surface

*BE05.30-N-1001-01B

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

*BE05.30-N-1014-01B

 Dial gage

*001589532100

 Dial indicator holder

*343589004000

 Dial indicator holder

*363589022100

If the measurements lie outside the permissible tolerance:



Check respective valve seat rings (see operation step 8). If the valve seat rings are OK, the intake or exhaust valves (6, 7) involved should be checked and machined or replaced if necessary (see operation steps 9, 10).

4

Remove valve spring retainers (2) and valve springs (3, 4)

Remove with valve lifter.



Remove valve springs (3, 4)

AR05.30-W-3510-03C

 Magnetic pin

*210589004000

 Valve lifter

*442589003100

 Adapter piece

*904589003100

Remove with valve tool kit.



Remove valve springs (3, 4)

AR05.30-W-3510-03D

 Magnetic pin

*210589004000

 Valve tool case

*541589006100

5

Pull off valve stem seals (9)

AR05.30-I-3510B

 Installation: Replace valve stem seals (9).

6

Pull intake and exhaust valves (6, 7) out of cylinder head (5)

 Mark installation position of the intake and exhaust valves (6, 7) in the cylinder head (5).

 Installation: Lubricate valve stems of the intake and exhaust valves (6, 7) with engine oil. Observe identification of intake and exhaust valves (6, 7).



Check

7

Check valve guides; replace if necessary

AR05.30-I-3731B

8

Perform visual inspection on valve seat rings

If the valve seats are burnt or stamped in:



Replace cylinder head.

9

Perform visual inspection on intake and exhaust valves (6, 7)

 The valve stem ends must not have any surface damage. Valve retainer grooves must not be worn out and the chrome layer on the valve stems must be complete. The valve seats must not be burnt.

If there are problems:



Replace respective intake or exhaust valve (6, 7).

10

Check intake and exhaust valves (6, 7) for wear, smooth operation and dimensional accuracy

 Straightening of valve stems of intake and exhaust valves (6, 7) is not permissible.

Valve seat angle

*BE05.30-N-1003-01B

Valve disk Ø

*BE05.30-N-1004-01B

Valve seat width on the valve disk

*BE05.30-N-1005-01B

Valve length

*BE05.30-N-1006-01B

Valve stem Ø

*BE05.30-N-1007-01B

Intake valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

*BE05.30-N-1008-01B

Exhaust valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

*BE05.30-N-1009-01B

Hardness at valve stem end

*BE05.30-N-1010-01B

Concentricity of valve seat to valve stem

*BE05.30-N-1011-01B

 Hardness tester

*000589202100

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

If specified values are not achieved:



Grind or replace valves if necessary.

AR05.30-I-4202B

11

Check valve springs (3, 4)

 Replace damaged valve springs (3, 4).

12

Install in the reverse order

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1009-01B

Exhaust valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

36,0

36,0

Dimension H

mm

2,5...3,2

2,5...3,2

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1001-01B

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 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1011-01B

Concentricity of valve seat to valve stem

Inlet

mm

0,03

0,03

Outlet

mm

0,03

0,03

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1003-01B

Valve seat angle

Inlet

°

20

20

Outlet

°

36

36

Outlet

°

45

45

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1006-01B

Valve length

Inlet

mm

125,70...126,10

128,45...129,05

Outlet

mm

152,20...152,90

152,20...152,90

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1004-01B

Valve disk Ø

Inlet

mm

33,9...34,1

33,9...34,1

Outlet

mm

37,9...38,1

37,9...38,1

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1005-01B

Valve seat width on the valve disk

Inlet  20°

mm

3,19

3,19

Outlet  20°

mm

–

–

Outlet  36°

mm

3,63

3,63

Outlet  45°

mm

3,35

3,35

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1007-01B

Valve stem Ø

Inlet

mm

7,935...7,950

7,935...7,950

Outlet

mm

7,925...7,940

7,925...7,940

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1008-01B

Intake valve seat surface machined dimension (H) relative to valve seat surface dia. (G)

Dimension G

mm

31,0

31,0

Dimension H

mm

2,7...3,1

2,7...3,1

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1010-01B

Hardness at valve stem end

Inlet

HRC

54...60

54...60

Outlet

HRC

54...60

54...60

Check values for valves

Number

Designation

ENGINE 904.9## ## up to 039739, ENGINE 906.9## ## up to 041955 except CODE MS8

ENGINE 904.9## ## as of 039740, ENGINE 906.9## ## as of 041956 except CODE MS8

BE05.30-N-1014-01B

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

mm

0,3

0,3