Replace valve stem seals.

AR05.30-D-3510NB

21.10.11

ENGINES 647.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINES 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

D05.30-1106-09

1 Valve keeper

2 Upper valve spring retainer

3 Valve spring

7  Cylinder leakage tester

8 Screw

9 Clamping claw

4 Valve stem seal

5 Lower valve spring retainer

6  Connection piece

D05.30-1108-06

1 Valve keeper

4 Valve stem seal

10  Magnetic pin

11  Valve assembly tool

12  Pliers

13 Protective sleeve

14  Drift

Modification notes

19.12.06

Bolt, tensioning claw to injector

Engine 647.981

*BA07.16-N-1003-01A

 	Remove/install
1	Remove camshaft housing		AR05.20-D-6995NA
2	Install retaining lock for crankshaft/starter ring gear		AR03.30-D-5000NA
3	Insert connection piece (6) in injector hole and clamp in place with clamping claw (9) and bolt (8)		*BA07.16-N-1003-01A
			*611589006300
4	Fit cylinder leakage tester (7) to connection piece (6)	 Calibrate cylinder leakage tester (7). Apply a pressure of about 5 bar to the cylinder to be machined.
			*611589006300
		Cylinder leakage tester (pressure loss) gotis://A_01_04.0
5	Put together assembly tool for valves (11) and install on the cylinder head	 Screw retaining fork (part 12) onto sealing surface of cylinder head cover in a thread and position thrust piece (part 7) vertically at upper valve spring retainer (2). In the case of valve springs (3) on intake valves of cylinder 5, retaining fork (part 12) must be screwed into the thread of the rearmost exhaust camshaft bearing.
		 Assembly together the assembly tool for valves (11) from parts in the case for the assembly tool for valves (separate part 3, 5, 7, 12, 19).	*111589256100
6	Press together valve spring (3) using assembly tool for valves (11) and remove split valve spring retainer locks (1) with a magnetic pin (10)	 Do not push out of the valve otherwise it could fall into the combustion chamber. Handle split valve spring retainer locks (1) carefully since these can fall into the oil pan through the oil return holes in the cylinder head.
		 Installation: Ensure correct seating of the split valve spring retainer locks (1) otherwise engine damage can be caused.
			*111589256100
			*210589004000
7	Remove the upper valve spring retainer (2) and the valve spring (3)	 Check upper valve spring retainer (2) for pitting, replace if necessary.
8	Pull off valve stem seal (4) using pliers (12)		*606589003700
		 Check valve stem for ridging and replace valves if there is ridging. See: 
		Remove/install valves	AR05.30-D-3511NB
		 Installation: Push protective sleeve (13) over the valve stem, lubricate valve stem seal (4) and push on with drift (14).
			*604589004300
9	Take off lower valve spring retainer (5)	 Check lower valve spring retainer (5) for pitting, replace if necessary.
10	Install in the reverse order

 Common rail diesel injection (CDI)

Number	Designation			Engine 647.981


BA07.16-N-1003-01A	Bolt, tensioning claw to injector	Stage 1	Nm	7
		Stage 2	°	180
		Stage 3	°	-

604 589 00 43 00

111 589 25 61 00

210 589 00 40 00

Drift

Magnetic pin

Case for valve installation tools

606 589 00 37 00

Pliers

Connector

611 589 00 63 00

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