Remove/install valves

AR05.30-T-3511A

Remove/install valves

19.10.09

 

Remove/install

1

Remove cylinder head

AR01.30-T-5800A

2

Remove nozzle holder and injection nozzle

AR07.03-T-6840A

3

Measure valve setback to cylinder head contact surface

Inspect valve setback at inlet and exhaust valve.

AR05.30-T-4100-01A

Valve setback relative to cylinder head contact surface

*BE05.30-N-1002-01H

Permissible difference between both valves must not be exceeded.

*BE05.30-N-1012-01H



*001589532100



*343589004000

 If the measurement obtained is not within the permissible tolerance 

Machine valve seat rings at inlet or exhaust valve, or

install new valve seat rings at inlet or exhaust valve.

AR05.30-T-3831A

4

Mount valve lifter (11) onto valve spring retainer (2)



*442589003100

5

Press down valve spring retainer (2) with valve lifter (11) and take off valve collets (1) with the magnetic pin

 Installation: Insert valve collets into the slot of the valve stem.

 Installation: Check valve spring (3, 5), valve spring retainer (2) and valve keepers (1) for correct seat.



*210589004000

6

Release pressure on valve lifter (11), take off valve spring retainer (2) and outer as well as inner valve springs (3, 5)

7

Pull valve stem seals (6) off valve guide

 Installation: Install new valve stem seals.

AR05.30-T-3510A

8

Take out washers (4, 7) of the outer and inner valve springs (3, 5)

9

Pull valves (9, 10) out of cylinder head

 Mark valves.

Installation: Oil valve stems with engine oil.

Note markings on valves.



Checking

10

Check valve guides for wear

- Visual inspection:

The valve guides must not have any surface damage.

- Use plug gauge to check inner diameter of valve guide.

 It must not be possible to insert the side of the plug gauge marked with '+' into the valve guide.

Valve guide inside diameter

*BE05.30-N-1001-01H

 Install new valve guides, if necessary.

AR05.30-T-3731A



*100589102100

11

Check valves for wear, radial trueness and dimensional accuracy

Inspection and machining dimensions of valves

AR05.30-W-4202-01B

Visual inspection:

The valve stem ends must not have any surface damage. The valve keyways must not be 'pounded-out' and the chrome layer on the valve stems must be complete. Valve seats must not be burnt.

Grind valves or install new valves, as necessary, it is not permitted to straighten the valves!

Valve seat angle "A"

*BE05.30-N-1003-01H

Valve disk Ø "B"

*BE05.30-N-1004-01H

Valve seat width at valve disk "F"

*BE05.30-N-1005-01H

Valve length "C"

*BE05.30-N-1006-01H

Valve stem Ø "E"

*BE05.30-N-1007-01H

Hardness of valve stem on shaft end

*BE05.30-N-1008-01H

Intake valve seat face machining dimension (H) in relation to valve seat face diameter (G)

*BE05.30-N-1009-01H

Exhaust valve seat face machining dimension (H) in relation to valve seat face diameter (G)

*BE05.30-N-1010-01H

Outside micrometer

12

Inspect valve seat rings at both inlet or exhaust valves

 If valve seat is only slightly worn, it can be reworked without replacing valve seat ring; otherwise the damaged valve seat ring must be replaced.

Replace valve seat rings

AR05.30-T-3831A

13

Test valve springs

 If problem exists, replace valve springs.

External length of valve spring without load

*BE05.30-N-1001-05D

Internal length of valve spring without load

*BE05.30-N-1002-05D

Length of valve spring when compressed with load of 330 up to 360 N

*BE05.30-N-1003-05D

Length of valve spring when compressed with load of 710 up to 770 N

*BE05.30-N-1004-05D

14

Install in the reverse order

 After installing, once again measure the valve setback and the permissible difference between both valves at the machined valves.
If the measurement obtained is not within the permissible tolerance 

Inspect valves at inlet or exhaust valve.

Number

Designation

Engines 447, 489

BE05.30-N-1001-01H

Valve lift with specified valve clearance

Intake

mm

13,8

Exhaust

mm

13,7

BE05.30-N-1002-01H

Valve setback relative to cylinder head contact surface

mm

0.7 to 1.1

BE05.30-N-1003-01H

Valve seat angle "A"

Intake

°

60

Exhaust

°

45

See picture

AR05.30-W-4202-01B

BE05.30-N-1004-01H

Valve disk Ø "B"

Intake

mm

58.8 to 59.0

Exhaust

mm

50.9 to 51.1

See picture

AR05.30-W-4202-01B

BE05.30-N-1005-01H

Valve seat width at valve disk "F"

New

Intake

mm

3.3 to 4.3

Exhaust

mm

3.5...4.5

Machining

Intake

mm

7,00

limit

Exhaust

mm

5,50

See picture

AR05.30-W-4202-01B

BE05.30-N-1006-01H

Valve length "C"

Intake

mm

142.3...142.7

Exhaust

mm

142.3...142.7

See picture

AR05.30-W-4202-01B

BE05.30-N-1007-01H

Valve stem Ø "E"

Intake

mm

11.932 to 11.950

Exhaust

mm

11.922 to 11.940

See picture

AR05.30-W-4202-01B

BE05.30-N-1008-01H

Hardness of valve stem on shaft end

HRC

54 to 60

BE05.30-N-1009-01H

Intake valve seat faces, machining dimension "H" in relation to
valve seat face Ø "G"

Dimension "G"

mm

54.99 to 55.01

New

Dimension "H"

mm

3.6 to 3.8

Machining
limit

Dimension "H"

mm

3,3

See picture

AR05.30-W-4202-01B

BE05.30-N-1010-01H

Outlet valve seat faces, machining dimension "H" in relation to
valve seat face Ø "G"

Dimension "G"

mm

47.99 to 48.01

New

Dimension "H"

mm

3.0 to 3.2

Machining
limit

Dimension "H"

mm

2,7

See picture

AR05.30-W-4202-01B

BE05.30-N-1012-01H

Permissible difference between valve setback to cylinder head separating surface

Intake

mm

 0,2

Exhaust

mm

 0,2

Number

Designation

Engine 447

Engine 489

BE05.30-N-1001-02F

Valve guide

Outside dia. (A)

Default

mm

18.028 to 18.046

18.028 to 18.046

Oversize 0.2

mm

18.235 to 18.256

18.235 to 18.256

Deviation 0.5

mm

18.535 to 18.556

18.535 to 18.556

Bore dia. in

Default

mm

18.000 to 18.018

18.000 to 18.018

Cylinder head (A)

Oversize 0.2

mm

18.200 to 18.221

18.200 to 18.221

Deviation 0.4

mm

18.400 to 18.421

18.400 to 18.421

Inside dia. (B)

pressed in

mm

12.000 to 12.027

12.000 to 12.027

Length (C)

mm

67,0

67,0

Distance (D) top edge

Intake

mm

17.1 to 17.5

17.1 to 17.5

of valve guide to
contact surface of valve spring

Exhaust

mm

17.1 to 17.5

17.1 to 17.5

See picture

AR05.30-T-3731-07A

AR05.30-T-3731-07A

Number

Designation

Engine 447

Engine 489

BE05.30-N-1001-05D

External length of valve spring without load

Part no.: 403 053 0120

mm

59

59

Part no.: 403 053 0320

mm

64

64

Part no.: 403 053 0820

mm

64

64

BE05.30-N-1002-05D

Internal length of valve spring without load

Part no.: 403 053 0622

mm

59

59

Part no.: 403 053 0822

mm

64

64

Part no.: 403 053 1122

mm

64

64

BE05.30-N-1003-05D

Length of valve spring when compressed with load of 330 up to 360 N

outer

mm

46,8

46,8

inner

mm

46,8

46,8

BE05.30-N-1004-05D

Length of valve spring when compressed with load of 710 up to 770 N

outer

mm

32,8

32,8

inner

mm

32,8

32,8