Check, remove/install valve guides

AR05.30-W-3731A

Check, remove/install valve guides

5.6.09

11.3.09

Exhaust valve spring, exhaust valve and exhaust valve seat ring modified, added.

Step 3

BT05.30-N-0004-01RH



Removing

1

Remove nozzle holder combination

Engine 904.904 up to engine end no. 040487 in model 670
engine 904.908 up to engine end no. 040487 in model 668, 670
engine 904.9 up to engine end no. 040487 in model 673, 674, 676

AR07.03-W-6831A

Engine 904.904 from engine end no. 040488 in model 670

Engine 904.908 from engine end no. 040488, 904.914/923/936 in model 668, 670

Engine 904.9 from engine end no. 040488 in model 673, 674, 676

Engine 904.9 in model 374, 375, 958, 970, 972, 975, 976

Engine 906.9 in model 374, 375, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976

AR07.03-W-6831C

2

Remove cylinder head (2)

Engine 904.904 in model 670

Engine 904.908/914/923/936 in model 668, 670

AR01.30-D-5800D

Engine 904.9 in model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

Engine 906.9 in model 374, 375, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976

AR01.30-W-5800A

3

Remove valves

AR05.30-W-3511A



Exhaust valve spring, exhaust valve and exhaust valve seat ring modified

BT05.30-N-0004-01RH

4

Take out support disks (4)

5

Clean the valve guides (1) using cylinder brush (3)



*000589106800



Check

6

Check the inside diameter (B) of valve guides (1) using drift (5)

*BE05.30-N-1003-02B



*102589002300

 If the side marked "+" of drift (5) can be inserted in valve guide (1), the related valve guide (1) must be replaced.

7

Lay cylinder head (2) on a suitable wooden block

 The combustion end of cylinder head (2) must face upward.

8

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



*103589031500

9

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

AR05.30-W-3731-09J

*BE05.30-N-1001-02B

*BE05.30-N-1002-02B

 Cylinder brush

*000589106800

 Dial indicator

*001589532100



Install

10

Turn the cylinder head (2) and place it on suitable support blocks

 The combustion end of the cylinder head (2) must face downward.

11

Ream the valve guide bores (1) in the cylinder head (2) to the next deviation using a suitable reamer (7)

 Only if the valve guides (1) are to be installed at the next deviation.

Engine 904.9 up to engine end no. 039739, engine 906.9 up to engine end no. 041955,
for 0.2 mm oversize use reamer (7) with Ø 13.2 mm H7

Engine 904.9 from engine end no. 039740, engine 906.9 from engine end no. 041956
for 0.2 mm oversize, use reamer (7) with Ø 14.2 mm H7 and for 0.5 mm oversize, use reamer (7) with Ø 14.5 mm H7

Only turn reamer (7) clockwise.

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

*BE05.30-N-1002-02B

12

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

 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 (1) using tongs

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

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

The protrusion (D) of valve guide (1) from the contact surface to the top edge of valve guide (1) is specified according to the installation position and length of the related sleeve (9); note the engine end no. and identification on the sleeve (9).

*BE05.30-N-1007-02B

For engine 904.9 up to engine end no. 039739 and engine 906.9 up to engine end no. 041955, use the following punch-in drift (8) and sleeve (9).



*904589011500

For engine 904.9 starting from engine end no. 039740 and engine 906.9 starting from engine end no. 041956, use the following punch-in drift (8) and sleeve (9).

 Insertion drift

*904589011500

 Sleeve

*904589086300

Valve guide overlap in cylinder head

*BE05.30-N-1005-02B

15

Remove punch-in drift (8) and sleeve (9)

16

Ream the bore in valve guide (1) in stages using adjustable reamer (10), until reamer (11) can be set at the bore in valve guide (1)

 Use an adjustable reamer (10) with Ø 7.2 to 8.0 mm. Only turn reamer (10) clockwise.

17

Ream the bore in valve guide (1) to the inside diameter (B) using reamer (11)

 Only turn reamer (11) clockwise.

*BE05.30-N-1003-02B



*000589215300

18

Clean the valve guides (1) using cylinder brush (3)



*000589106800

19

To test them, lubricate the valve stems with engine oil and push the valves into valve guides (1)

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

20

Insert support disks (4)

21

Install valves

AR05.30-W-3511A

22

Install cylinder head (2)

Engine 904.904 in model 670

Engine 904.908/914/923/936 in model 668, 670

AR01.30-D-5800D

Engine 904.9 in model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

Engine 906.9 in model 374, 375, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976

AR01.30-W-5800A

23

Install nozzle holder combination

Engine 904.904 up to engine end no. 040487 in model 670
engine 904.908 up to engine end no. 040487 in model 668, 670
engine 904.9 up to engine end no. 040487 in model 673, 674, 676

AR07.03-W-6831A

Engine 904.904 from engine end no. 040488 in model 670

Engine 904.908 from engine end no. 040488, 904.914/923/936 in model 668, 670

Engine 904.9 from engine end no. 040488 in model 673, 674, 676

Engine 904.9 in model 374, 375, 958, 970, 972, 975, 976

Engine 906.9 in model 374, 375, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976

AR07.03-W-6831C

Number

Designation

Engine
904.9 up to
end no. 039739,

Engine
906.9 up to
end no. 041955

Engine
904.9 as of
end no. 039740
except engine
904.941,

Engine
906.9 as of
end no. 041956

BE05.30-N-1001-02B

Outside dia.

Default

mm

13.028...13.046

14.028...14.046

Oversize 0.2

mm

13.228...13.246

14.228...14.246

Deviation 0.5

mm

-

14.528...14.546

BE05.30-N-1002-02B

Bore dia. in cylinder head

Default

mm

13.000...13.018

14.000...14.018

Oversize 0.2

mm

13.200...13.218

14.200...14.218

Deviation 0.5

mm

-

14.500...14.518

BE05.30-N-1003-02B

Inside dia. (machined dimension)

mm

8.000...8.022

8.000...8.022

BE05.30-N-1005-02B

Overlap in cylinder head

mm

0.010...0.046

0.010...0.046

BE05.30-N-1007-02B

Protrusion of valve guide from contact surface at top edge of valve guide

Inlet

mm

14.1...14.5

13.7...14.5

Outlet

mm

17.6...18.0

17.2...18.0