Remove/install valves

AR05.30-S-3511SE

Remove/install valves

20.02.2019

Engine

642 in model 470, 471

Engine

642 in model 639

Modification notes

19.02.2019

Work procedure separated and revised, special tools added.

The whole document

1

Assembly device

4

Depressor

6

Lever

2

Counterholder

5

Sliding piece

8

Cylinder head

3

Assembly lever

4

Depressor

10

Valve keeper

12

Valve spring

7

Magnetic finger

11

Upper valve spring retainer

13

Lower valve spring retainer

9

Valve

 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-P-5000-01A

Preparatory tasks

1

Remove respective cylinder head (8).

Remove/install left cylinder head
Model 470, 471

AR01.30-S-5770PS

Remove/install right cylinder head Model 470, 471

AR01.30-S-5780PS

Remove / install cylinder headsModel 639

AR01.30-S-5795SE

2

Remove respective exhaust manifold.

Remove/install left exhaust manifold
Model 470, 471

AR14.10-S-3007PS

Remove/install right exhaust manifold Model 470, 471

AR14.10-S-3008PS

Remove/install exhaust manifoldModel 639

AR14.10-S-3915SE

3

Attach cylinder head (8) to assembly device (1).


Before commissioning the  assembly device (1), ensure that the counterholders (2) are attached correctly to the cylinder head (8).
Otherwise, there is a danger that the cylinder head (8) will be pressed upward out of the  assembly device (1) and the cylinder head (8) and valves (9) will be damaged.

 Observe operator's manual for the  assembly device (1).

 Assembly tool

*271589005900

4

Attach assembly lever (3) with depressor (4) to the sliding piece (5).

 Position  depressor (4) vertically at upper valve spring retainer (11) and align sliding piece (5).

 Valve assembly tools kit

*111589256100

 Assembly tool

*271589005900

 Depressor

*640589006100

Remove

5

Move the air bellows of the assembly device (1) with the lever (6) so that the air bellows coincides with the combustion chamber of the valves (9).


Ensure that the air bellows always coincides correctly with the combustion chamber and is pushed in the center.
The air bellows may otherwise be pushed out of the side of the combustion chamber and this leads to damage to the valves (9).

 Observe operator's manual for the  assembly device (1).

 Assembly tool

*271589005900

6

Connect compressed-air supply system to assembly device (1).

 Assembly tool

*271589005900

7

Open compressed air valve on assembly device (1).

 Observe operator's manual for the  assembly device (1).
The air bellows presses in the combustion chamber on the valve disk.

 Assembly tool

*271589005900

8

Press the valve spring (12) together with the depressor (4) and remove the valve keepers (10) with the magnetic finger (7).

 Valve assembly tools kit

*111589256100

 Magnetic finger

*116589066300

 Depressor

*640589006100

9

Remove the top valve spring retainer (11) with the valve spring (12) and the bottom valve spring retainer (13).

10

Remove valve stem seal with pliers.

AR05.30-S-3500-02SE


Detach valve stem seal using only  pliers.
Otherwise the valve stem or the valve (9) will be damaged.

 Pliers

*606589003700

11

Close compressed air valve on assembly device (1).

 Assembly tool

*271589005900

12

Relieve pressure in the air bellows of the assembly device (1).

 Observe operator's manual for the  assembly device (1).

 Assembly tool

*271589005900

13

Perform the operation steps when removing further valves (9) in the same way.

 Operation steps 5 to 12.

14

Remove valves (9).

 To do this, remove cylinder head (8) from the  assembly device (1).

 Assembly tool

*271589005900



Check

15

Perform a visual inspection of all components of the valve drive.

Depending on the findings,



Replace damaged components.



Install

16

Insert valves (9) in cylinder head (8) and attach cylinder head (8) to assembly device (1).

 Assembly tool

*271589005900

17

Move air bellows of the assembly device (1) with the lever (6) so that the air bellows is aligned above the combustion chamber with the respective valves (9).


Ensure that the air bellows for the  assembly device (1) always correctly coincides with the combustion chamber and is pushed in the center.
The air bellows may otherwise be pushed out of the side of the combustion chamber and this leads to damage to the valves (9).

 Observe operator's manual for the  assembly device (1).

 Assembly tool

*271589005900

18

Open compressed air valve on assembly device (1).

 Observe operator's manual for the  assembly device (1).
The air bellows of the   assembly device (1) press in the combustion chamber onto the valve disks.

 Assembly tool

*271589005900

19

Install valve stem seal.

AR05.30-S-3500-02SE

 Drift

*604589004300

20

Insert top valve spring retainer (11) with the valve spring (12) and bottom valve spring retainer (13).

21

Press together the valve spring (12) with the depressor (4) and insert the valve keepers (10) with the magnetic finger (7).

 Valve assembly tools kit

*111589256100

 Magnetic finger

*116589066300

 Depressor

*640589006100

22

Close compressed air valve on assembly device (1).

 Assembly tool

*271589005900

23

Relieve pressure in the air bellows of the assembly device (1).

 Observe operator's manual for the  assembly device (1).

 Assembly tool

*271589005900

24

Perform the operation steps when installing further valves (9) in the same way.

 Operation steps 17 to 23.

Final activities

25

Disconnect compressed-air supply system from assembly device (1).

 Assembly tool

*271589005900

26

Remove assembly lever (3) with depressor (4) from the sliding piece (5).

 Valve assembly tools kit

*111589256100

 Assembly tool

*271589005900

 Depressor

*640589006100

27

Remove cylinder head (8) from assembly device (1).

 Assembly tool

*271589005900

28

Install respective exhaust manifold.

Remove/install left exhaust manifold
Model 470, 471

AR14.10-S-3007PS

Remove/install right exhaust manifoldModel 470, 471

AR14.10-S-3008PS

Remove/install exhaust manifoldModel 639

AR14.10-S-3915SE

29

Install respective cylinder head (8).

Remove/install left cylinder head
Model 470, 471

AR01.30-S-5770PS

Remove/install right cylinder headModel 470, 471

AR01.30-S-5780PS

Remove / install cylinder headsModel 639

AR01.30-S-5795SE