Check, remove/install valve guides

AR05.30-I-3731B

23.5.13

ENGINE

904.941 in MODEL 684.482

1	Valve guide
2	Cylinder head
A	Bore dia. (in cylinder head)
A1	Outside dia. (valve guide)
B	Inside dia. (valve guide)
C	Length (valve guide)
D	Protrusion (valve guide)

W05.30-0003-06

G05.30-3164-09

1	Valve guide	4	Staged drift	7	Reamer (adjustable)
2	Cylinder head	5	Reamer (adjustable)	8	Reamer
3	Drift	6	Sleeve

	Remove
1	Remove valves		AR05.30-I-3511B
2	Remove valve stem seals		AR05.30-I-3510B
3	Remove supporting discs for valve springs.
	Check
4	Check valve guides (1) for surface damage	If a valve guide (1) has surface damage:
		
		Mark the corresponding valve guide (1).
5	Check valve guides (1) inside dia. (B) using a drift (3)	 Drift	*102589002300
		If it is possible to insert side of drift (3) marked with "+" into valve guide (1):
		
		Mark the corresponding valve guide (1).
		If in this and the previous operation step no damaged valve guides (1) were established:
		
		Continue with operation step 14
	Remove
6	Remove marked, damaged valve guides (1) from the combustion side out of the cylinder head (2)	 Staged drift	*103589031500
	Check
7	Check respective bore dia. (A) in cylinder head (2)	Bore dia. in cylinder head	*BE05.30-N-1002-02B
		If one or more bore diameters (A) deviate from the prescribed values:
		
		Ream out respective hole to the next deviation or replace cylinder head (2).
		 The reamer (5) must only be turned clockwise.
		 Note overlap of valve guide (1) with respect to cylinder head (2).
		Overlap in cylinder head	*BE05.30-N-1005-02B
		Outside dia.	*BE05.30-N-1001-02B
		 Reamer	*000589185300
	Install
 Danger !	Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.	Wear heat protective gloves, protective clothing and full eye protection. Ensure that the work area is adequately ventilated.	AS00.00-Z-0003-01A
8	Place new valve guides (1) in the supercooling box and pour in liquid nitrogen	 If bore in cylinder head (2) has been machined, use valve guide (1) with an appropriate deviation.
		 Supercool the valve guides (1) for about 20 to 30 min.
		 Supercooler box	*346589006300
 Danger !	Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
9	Heat cylinder head (2) in water bath	 Temperature approx. 80°C.
 Danger !	Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.	Wear heat protective gloves, protective clothing and full eye protection. Ensure that the work area is adequately ventilated.	AS00.00-Z-0003-01A
10	Using pliers, take out valve guides (1) from the cooling box and press into the heated cylinder head (2) using the punch-in drift and the sleeve (6)	 The protrusion (D) for the intake or exhaust valve is dependent on the installation position of the sleeve (6). Note marking on the sleeve (6).
		Protrusion of valve guide from contact surface at top edge of valve guide	*BE05.30-N-1007-02B
		 Sleeve	*904589086300
		 Drift punch	*904589011500
11	Ream out new valve guides (1)	 The reamers (7, 8) must only be turned clockwise. First ream out using the adjustable reamer (7) to a diameter of 7.95 mm then ream out with the reamer (8) to the prescribed inside diameter.
		Inside dia. (machined dimension)	*BE05.30-N-1003-02B
		 Reamer	*000589215300
12	Clean new valve guides (1) with a cleaning brush
	Check
13	Check valve guides inside dia. (B) using a drift (3)	 Repeat operation steps 11 to 13 if necessary or replace valve guide (1).
		 Drift	*102589002300
	Install
14	Install supporting discs for valve springs.
15	Install valve stem seals.		AR05.30-I-3510B
16	Install valves		AR05.30-I-3511B

Test values for valve guides

Number	Designation			Engine 904.941 in model 684
BE05.30-N-1002-02B	Bore dia. in cylinder head	Default	mm	14,000...14,018
		Oversize 0.2	mm	14,200...14,218
		Deviation 0.5	mm	–

Test values for valve guides

Number	Designation			Engine 904.941 in model 684
BE05.30-N-1001-02B	Outside dia.	Default	mm	14,028...14,046
		Oversize 0.2	mm	14,228...14,246
		Deviation 0.5	mm	–

Test values for valve guides

Number	Designation		Engine 904.941 in model 684
BE05.30-N-1005-02B	Overlap in cylinder head	mm	0,010...0,046

Test values for valve guides

Number	Designation			Engine 904.941 in model 684
BE05.30-N-1007-02B	Protrusion of valve guide from contact surface at top edge of valve guide	Inlet	mm	13,7...14,5
		Outlet	mm	17,2...18,0