Check, remove/install valve guides

AR05.30-W-3731B

Check, remove/install valve guides

13.3.08

18.12.07

Measure valve guides (2) and bores in cylinder head (1) , modified.

Step 9

AR05.30-W-3731-09J

Modified valve stem seal and valve guide, added.

Step 12

BT05.30-W-0001-02G

Supercool the valve guides with solid carbon dioxide (dry ice), added.

Steps 13 and 14



Removing

1

Remove nozzle holder combination

AR07.03-W-6831B

2

Remove cylinder head (1)

AR01.30-W-5800B

3

Remove valves

AR05.30-W-3511B

4

Take out support disks (5)

5

Clean valve guides (2) using a cylinder brush (4)



*000589106800



Checking

6

Check the inside diameter (B) of valve guides (2) using drift (3)

*BE05.30-N-1001-02C



*117589032300

 If the side marked "+" of the drift (3) can be inserted in valve guide (2), the related valve guide (2) must be replaced.

7

Lay cylinder head (1) on a suitable wooden block

 The combustion end of cylinder head (1) must face upward.

8

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



*103589021500

9

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

AR05.30-W-3731-09G

*BE05.30-N-1004-02C

*BE05.30-N-1005-02C

 Cylinder brush

*000589106800

 Dial indicator

*001589532100



Install

10

Turn the cylinder head (1) and place it on suitable support blocks

 The combustion end of the cylinder head (1) must face downward.

11

Ream the valve guide bores (2) in the cylinder head (1) to the next oversize using the corresponding reamer (7)

 Only if valve guides (2) at the next oversize are to be installed.

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

*BE05.30-N-1005-02C

For 0.2 mm oversize use reamer (7) with Ø 15.2 mm H7, and for 0.4 mm oversize use reamer (7) with Ø 15.4 mm H7. Only turn reamer (7) clockwise.

12

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

 Allocate only the modified valve guides (2).



Valve stem seal and valve guide modified

As of engine end no. 513886

BT05.30-W-0001-02G

 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 (2) using tongs

 The valve guides (2) must be completely covered by the solid carbon dioxide (dry ice). Supercool the valve guides (2) 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 guide (2) out of the cooling box using the tongs, push sleeve (9) over valve guide (2) and knock valve guide (2) into cylinder head (1) using drift (8)

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

The gap (D) from the top edge of valve guide (2) to the contact surface of the valve spring is specified according to the installation position of sleeve (9).

*BE05.30-N-1007-02C

Valve guide overlap in cylinder head

*BE05.30-N-1002-02C



*541589004300

15

Remove drift (8) and sleeve (9)

16

Ream the bore in valve guide (2) in stages using adjustable reamer (10), until reamer (11) can be set at the bore in valve guide (2)

 Use an adjustable reamer (10) with Ø 8.4 to 9.0 mm. Only turn reamer (10) clockwise.

17

Ream the bore in valve guide (2) to the inside diameter (B) using reamer (11)

 Only turn reamer (11) clockwise.

*BE05.30-N-1001-02C



*000589105300

18

Clean valve guides (2) using a cylinder brush (4)



*000589106800

19

To test them, lubricate the valve stems with engine oil and push the valves into valve guides (2)

 If used valves are being reinstalled, the markings made on cylinder head (1) and on the valves must be observed. The valve stems must make smooth contact all round the inside of the valve guides (2).

20

Insert support disks (5)

21

Install valves

AR05.30-W-3511B

22

Install cylinder head (1)

AR01.30-W-5800B

23

Install nozzle holder combination

AR07.03-W-6831B

Number

Designation

Engine 541.9, 542.9

BE05.30-N-1001-02C

Inside Ø pressed in

Default

mm

9.000 to 9.022

Wear limit

mm

9.050

BE05.30-N-1002-02C

Valve guide overlap in cylinder head

mm

0.010 to 0.046

BE05.30-N-1004-02C

Outside Ø

Default

mm

15.028 to 15.046

Oversize 0.2

mm

15.228 to 15.246

Deviation 0.4

mm

15.428 to 15.446

BE05.30-N-1005-02C

Bore Ø in cylinder head

Default

mm

15.000 to 15.018

Oversize 0.2

mm

15.200 to 15.218

Deviation 0.4

mm

15.400 to 15.418

BE05.30-N-1007-02C

Distance of top edge of valve guide to contact surface of valve spring

Inlet

mm

19.65 to 20.95

Outlet

mm

19.65 to 20.95