Check, remove/install valve guides

AR05.30-W-3731C

Check, remove/install valve guides

13.3.08

10.3.08

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

Step 9

AR05.30-W-3731-09G

Valve stem seal and valve guide changed, added.

Step 12

BT05.30-W-0001-02G

Cool valve guides using carbon dioxide (dry ice), added.

Steps 13 and 14



Removing

1

Remove nozzle holder combination

AR07.03-W-6831D

2

Remove cylinder head (1)

AR01.30-W-5800C

3

Remove valves

AR05.30-W-3511C

4

Remove support washers (5)

5

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



*000589106800



Checking

6

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

*BE05.30-N-1003-02L



*117589032300

 If it is possible to insert the side of the drift (3) marked with "+" into the valve guide (2), the respective valve guide (2) has to be replaced.

7

Lay cylinder head (1) on a suitable wooden block

 The combustion side on the cylinder head (1) must face upwards.

8

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



*103589021500

9

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

AR05.30-W-3731-09G

*BE05.30-N-1001-02L

*BE05.30-N-1002-02L

 Cylinder brush

*000589106800

 Dial indicator

*001589532100



Install

10

Turn cylinder head (1) and place on suitable wooden blocks

 The combustion side on the cylinder head (1) must face downwards.

11

Ream bores for valve guides (2) in cylinder head (1) using a corresponding reamer to the next larger deviation

 Only when valve guides (2)can be installed with the next largest deviation.

Note deviations of bore diameter in cylinder head (A).

*BE05.30-N-1002-02L

At deviation 0,2 mm use reamer (7) with a 15.2 mm dia. H7 and for a deviation of

0,4 mm, use reamer (7) with a 15.4 mm H7 dia. Only turn reamer (7) clockwise.

12

Assign and mark new valve guides (2) to bores in cylinder head (1)

 Assign modified valve guides (2) only.



Valve stem seal and valve guide modified

As of engine end no. 111125

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

Add carbon dioxide (dry ice) to cooling box and insert new valve guides (2) using pliers

 The valve guides (2) must be completely covered by carbon dioxide (dry ice). Cool valve guides (2) for approx. 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

Use pliers to remove valve guide (2) from cooling box, slide bushing (9) over the valve guide (2) and drive the valve guide (2) using a drift (8) into the cylinder head (1)

 Assign and mark valve guides (2) relative to bores in cylinder head (1).

 The distance (D) from the upper edge of the valve guide (2) relative to the contact surface of the valve springs is specified to match the installation position of the bushing (9).

*BE05.30-N-1005-02L

Valve guide overlap in cylinder head

*BE05.30-N-1007-02L



*541589004300

15

Remove drift (8) and bushing (9)

16

Ream out bore in valve guide (2) using an adjustable reamer (10) in stages until reamer (11) can be placed on bore in valve guide (2)

 Use adjustable reamer (10) with a dia. of 8.4 to 9.0 mm. Only turn reamer (10) clockwise.

17

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

 Only turn reamer (11) clockwise.

*BE05.30-N-1003-02L



*000589105300

18

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



*000589106800

19

Lubricate valve stems of valves using engine oil and slide valves into the valve guides (2) for inspection

 If worn valves are installed again, the markings made on the cylinder head (1) and valves must be noted.

The valve stems must make smooth contact all round in the valve guides (2).

20

Insert support washers (5)

21

Install valves

AR05.30-W-3511C

22

Install cylinder head (1)

AR01.30-W-5800C

23

Install nozzle holder combination

AR07.03-W-6831D

Number

Designation

Engine
457.9

BE05.30-N-1001-02L

Outside Ø

Default

mm

15.028...15.046

Oversize 0.2

mm

15.228...15.246

Deviation 0.4

mm

15.428...15.446

BE05.30-N-1002-02L

Bore diameter in cylinder head

Default

mm

15.000...15.018

Oversize 0.2

mm

15.200...15.218

Deviation 0.4

mm

15.400...15.418

BE05.30-N-1003-02L

Inside diameter pressed in

Default

mm

9.000...9.022

Wear limit

mm

9.050

BE05.30-N-1005-02L

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

Inlet

mm

19.65...20.95

Outlet

mm

19.65...20.95

BE05.30-N-1007-02L

Valve guide overlap in cylinder head

mm

0.010...0.046