Removal and Replacement

Remove/Install Valves






DANGER:
- Lethal injuries are possible if vehicle slips off of lifting platform.
- Align vehicle between the columns of the the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.


1 Remove cylinder head (1)
2 Mount cylinder head (1) on assembly board (2) with the relevant insertion plate (3)

NOTE:
- Put the insertion plate (2) with the arrow indicating the driving direction (4) pointing towards the front and with the corresponding side (R, L), into the assembly board (2).
- Screw in cylinder head (1) with its front end pointing toward arrow indicating the driving direction (5) with one screw each (6) on front and rear of assembly board (2)
- The cylinder head (1) can be mounted on the assembly board (2) without unscrewing the exhaust manifold.

3 Attach assembly tool (7) for valves at the cylinder head (1) and position vertically on the valve spring plate (8)

NOTE: Use parts (2, 3, 4, 5, 7, 14, 19) from valve assembly tool case.

4 Remove valve disk (top) (8) and valve disk (bottom) (11).

NOTE:
- Press together valve spring (9) with assembly tool (7), remove split valve spring retainer locks (10).
- Check valve disk (top) (8) and valve disk (bottom) (11) for formation of burrs, replace if necessary.
- The valve springs (9) of the intake and the exhaust valves are identical.

5 Use pliers (15) to remove valve stem seals (12)

NOTE: Installation: Fit protective sleeve (13) onto the valve stem. Oil valve stem seals (12) and press on with assembly drift (16). The protective sleeve (13) must be removed from the valve stem after the valve stem seal (12) has been pressed on.

6 Take cylinder head (1) off assembly board (2)

DANGER:
- Risk of explosion and poisoning from melting down and improper handling of sodium-filled valves. Risk of injury from burns and caustic burns to skin sections in the event of contact with sodium.
- Do not open sodium-filled valves; if necessary, wear protective gloves and eye protection if valves are damaged.


7 Remove valve (14)

NOTE: Installation: Check surface of valve stems for roughness and ridging (visual inspection or with a nail). Replace valves with rough stem surface or burrs.
- Grind in new or re-used valves with valve grinding-in paste before installing.

8 Inspect valves

CAUTION: The intake and exhaust valves must not be machined.

- If the given tolerances fall short, the valve must be replaced.

9 Inspect the valve guides, replace if necessary.
10 Install in the reverse order.