Remove/Install Valves - Ar05.30-D-3511TSV

Engine 642 in model 907

	Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Preparatory tasks
1	Remove respective cylinder head (8).	Remove/install left cylinder head	AR01.30-D-5770TSV
		Remove/install right cylinder head	AR01.30-D-5780TSV
2	Remove respective exhaust manifold.	Remove/install left exhaust manifold	AR14.10-D-3007TSV
		Remove/install right exhaust manifold	AR14.10-D-3008TSV
3	Attach cylinder head (8) to assembly device (1).	Before commissioning the assembly device (1), ensure that the counterholders (2) are attached correctly to the cylinder head (8). Risk otherwise exists that cylinder head (8) will be pressed upwards out of assembly device (1) and cylinder head (8) and/or valves (9) will be damaged. Observe operator's manual for the assembly device (1).
		Assembly tool	Fig 1
4	Attach assembly lever (3) with depressor (4) to the sliding piece (5).	Position depressor (4) vertically at upper valve spring retainer (11) and align sliding piece (5).
		Valve assembly tools kit	Fig 2
		Assembly tool	Fig 1
		Depressor	Fig 6
	Remove
5	Move air bellows of the assembly device (1) with the lever (6) so that the air bellows is aligned above the combustion chamber with the respective valves (9).	Ensure that the air bellows for the assembly device (1) always correctly coincides with the combustion chamber and is pushed in the center. The air bellows may otherwise be pushed out of the side of the combustion chamber and this leads to damage to the valves (9). Observe operator's manual for the assembly device (1).
		Assembly tool	Fig 1
6	Connect compressed-air supply system to assembly device (1).	Assembly tool	Fig 1
7	Open compressed air valve on assembly device (1).	Observe operator's manual for the assembly device (1). The air bellows of the assembly device (1) press in the combustion chamber onto the valve disks.
		Assembly tool	Fig 1
8	Press together valve spring (12) and remove valve keepers (10) using magnetic finger (7).	Valve assembly tools kit	Fig 2
		Magnetic finger	Fig 4
		Depressor	Fig 6
9	Remove upper valve spring retainer (11) with valve spring (12) and lower valve spring retainer (13).
10	Remove valve stem seal with pliers.		AR05.30-D-3500-03TSV
		Detach valve stem seal using only pliers. Valve stem and/or valve (9) will otherwise be damaged.
		Pliers	Fig 5
11	Close compressed air valve on assembly device (1).	Assembly tool	Fig 1
12	Relieve pressure in the air bellows of the assembly device (1).	Observe operator's manual for the assembly device (1).
		Assembly tool	Fig 1
13	Perform the operation steps when removing further valves (9) in the same way.	Operation steps 5 to 12.
14	Remove cylinder head (8) from assembly device (1) and remove valves (9).	Assembly tool	Fig 1
	Check
15	Perform a visual inspection of all components of the valve drive.	Depending on the findings, ↓ Replace damaged components.
	Install
16	Insert valves (9) in cylinder head (8) and attach cylinder head (8) to assembly device (1).	Assembly tool	Fig 1
17	Move air bellows of the assembly device (1) with the lever (6) so that the air bellows is aligned above the combustion chamber with the respective valves (9).	Ensure that the air bellows for the assembly device (1) always correctly coincides with the combustion chamber and is pushed in the center. The air bellows may otherwise be pushed out of the side of the combustion chamber and this leads to damage to the valves (9). Observe operator's manual for the assembly device (1).
		Assembly tool	Fig 1
18	Open compressed air valve on assembly device (1).	Observe operator's manual for the assembly device (1). The air bellows of the assembly device (1) press in the combustion chamber onto the valve disks.	3
		Assembly tool	Fig 1
19	Install valve stem seal.		AR05.30-D-3500-03TSV
		Drift	Fig 3
20	Insert upper valve spring retainer (11) with valve spring (12) and lower valve spring retainer (13).
21	Press together valve spring (12) and insert valve keepers (10) using magnetic finger (7).	Valve assembly tools kit	Fig 2
		Magnetic finger	Fig 4
		Depressor	Fig 6
22	Close compressed air valve on assembly device (1).	Assembly tool	Fig 1
23	Relieve pressure in the air bellows of the assembly device (1).	Observe operator's manual for the assembly device (1).
		Assembly tool	Fig 1
24	Perform the operation steps when installing further valves (9) in the same way.	Operation steps 17 to 23.
	Final activities
25	Disconnect compressed-air supply system from assembly device (1).	Assembly tool	Fig 1
26	Remove assembly lever (3) with depressor (4) from the sliding piece (5).	Valve assembly tools kit	Fig 2
		Assembly tool	Fig 1
		Depressor	Fig 6
27	Remove cylinder head (8) from assembly device (1).	Assembly tool	Fig 1
28	Install respective exhaust manifold.	Remove/install left exhaust manifold	AR14.10-D-3007TSV
		Remove/install right exhaust manifold	AR14.10-D-3008TSV
29	Install respective cylinder head (8).	Remove/install left cylinder head	AR01.30-D-5770TSV
		Remove/install right cylinder head	AR01.30-D-5780TSV

Fig 1: Assembly Tool (271 589 00 59 00)

Fig 2: Valve Assembly Tools Kit (111 589 25 61 00)

Fig 3: Drift (604 589 00 43 00)

Fig 4: Magnetic Finger (116 589 06 63 00)

Fig 5: Pliers (606 589 00 37 00)

Fig 6: Depressor (640 589 00 61 00)