Remove/install valves

AR05.30-B-3511E

Remove/install valves

12.02.16



Removing and installing

1

Remove cylinder head (5).

AR01.30-B-5800F

2

Remove the injection nozzle holders

AR07.03-B-6831B

3

Measure distance between valve faces and cylinder head face (valve recess).

Should the obtained measuring not be within the recommended values:



- replace the intake valve and/or machine again or replace the valve seat;

- replace or machine the exhaust valve and/or the valve seat.

AR05.30-B-4100-01D

Distance between the valve and the cylinder head bottom face.

*BE05.30-B-1001-01D



*001589532100



*343589004000

4

Place the head (5) on he fastening device



*442589046300

5

Insert the valve removal device (8) in the threaded orifice of the head (5)



*442589003100

6

Press the valves spring plate (2) with the valve removal tool (8) and remove the tapered keys (1)

When removing the taper keys (1) preferably use a magnetized tool.

Install: After installing the taper keys (1), check their perfect locking.

7

relieve the valve removal tool (8) and remove the plate (2), the spring (3) and the thrust washer (4)

8

Remove the seal (9) from the valve rod (6, 7) from the head (5)

 Replace seal whenever the seal and/or the valve is removed.

AR05.30-B-3510D

9

Turn cylinder head upside down and remove valve (6, 7).

 Mark the valves (6, 7).

Install: Lubricate valve stem with engine oil. Observe the markings on the valves (6, 7).



Check

10

Check the inner diameter of the valve guide using the caliper (12)



*636589002100

In case of irregularity, replace valve guide.

AR05.30-B-3731D

Internal valve guide diameter.

*BE05.30-B-1003-02B

11

Check the condition and dimensions of the valve (6, 7)

Replace valves if they show signs of wear on key grooves, damages on their ends and to stem chromium layer and burned seat.

AR05.30-B-4202-01A

*BE05.30-B-1003-01D

*BE05.30-B-1004-01D

*BE05.30-B-1005-01D

*BE05.30-B-1006-01D

*BE05.30-B-1007-01D

*BE05.30-B-1008-01D

*BE05.30-B-1009-01D

Outer micrometer, from 0 to 25 mm

Do not machine the intake valve. In case of damage/wear, replace it.

If necessary, machine or replace the exhaust valve.

AR05.30-B-4202C

12

Check valve seat for condition.

In case of slight deformation on the seat surface, it is possible to machine the seat ring, provided the distance from the valve to the cylinder head, after machining, is greater or equal to the minimum permissible.

If necessary, rework seat.

AR05.30-B-4511E

If necessary, replace seat.

AR05.30-B-3831D

13

Check the valve spring pressure (3)

*BE05.30-B-1001-05D

Spring test

14

Install in reverse order

Número

Denominação

Engine 457.9; 460.984

BE05.30-B-1001-01D

Distance between the valves faces and the head

Intake

Normal

mm

0.7...1.1

Maximum repair

mm

1.6

Exhaust

Normal

mm

0.7...1.1

Maximum repair

mm

1.6

BE05.30-B-1003-01D

Valve seat face angle

Intake

degrees

-

Intake

degrees

30

Exhaust

degrees

-

Exhaust

degrees

45

BE05.30-B-1004-01D

Valve head diameter

Intake

mm

45.3...45.7

Exhaust

mm

40.9...41.3

BE05.30-B-1005-01D

Valve seat face width

Intake

20-degree angle

mm

-

Intake

30-degree angle

3.5...4.5

Exhaust

20-degree angle

mm

-

Exhaust

36-degree angle

mm

-

Exhaust

45-degree angle

mm

3.5...4.5

BE05.30-B-1006-01D

Valve length

Intake

mm

145.0

Exhaust

mm

145.0

BE05.30-B-1007-01D

Valve rod diameter

Intake

mm

8.935...8.950

Exhaust

mm

8.925...8.940

BE05.30-B-1008-01D

Control diameter in the relative position of the intake valve

Diameter G

mm

42.0

Position H (new)

mm

3.95...4.25

Position H (minimum after rework)

mm

2.9 (or larger)

BE05.30-B-1009-01D

Control diameter in the relative position of the exhaust valve

Diameter G

mm

39.0

Position H (new)

mm

3.0...3.3

Position H (minimum after rework)

mm

2.3

Número

Denominação

Engine 457.9; 460.984

BE05.30-B-1003-02B

Valve guide internal diameter (final finishing)

Normal

mm

9.000...9.022

wear limit

mm

9.050

Número

Denominação

Engine 457.9

BE05.30-B-1001-05D

Exhaust and intake valve springs

Unloaded length

mm

73,6

Length under load from 382 to 418 N

mm

49

Length under load of 644 to 706 N

mm

37,0

Diameter of spring wire

mm

4,35

Inside diameter of spring

mm

24,5...24,9

Outside diameter of spring

mm

33,40