AR05.30-W-3731G Check, remove/install valve guides 13.3.

08
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934

1 Cylinder head
2 Valve guide
3 Drift
4 Cylinder brush
5 Base washer
6 Stepped driver

B Inside diameter

W05.30-1125-06

W05.30-1088-09

1 Cylinder head 9 Bushing A Bore diameter in cylinder head

2 Valve guide 10 Reamer (adjustable) B Inside diameter
7 Reamer 11 Reamer D Distance
8 Drift

Modification notes
18.12.07 Measure valve guides (2) and bores in cylinder head (1) , Step 9 AR05.30-W-3731-09G
modified.
Modified valve stem seal and valve guide, added. Step 12 BT05.30-W-0001-02G
Supercool the valve guides with solid carbon dioxide (dry Steps 13 and 14
ice), added.

Removing
© Daimler AG, 10/28/09, G/09/09 / ar05.30-w-3731g / Check, remove/install valve guides Page 1/3
ENGINE 541.9 in MODEL 930, 932, 933, 934 ENGINE 542.9 in MODEL 930, 932, 934
1 Remove nozzle holder combination AR07.03-W-6831G
2 Remove cylinder head (1) AR01.30-W-5800G
3 Remove valves AR05.30-W-3511G
4 Take out support disks (5)
5 Clean valve guides (2) using a cylinder *000589106800
brush (4)
Checking
6 Check the inside diameter (B) of valve *BE05.30-N-1001-02C
guides (2) using drift (3)
*117589032300
If the side marked "+" of drift (3) can be
inserted in valve guide (2), the related valve
guide (2) must be replaced.
7 Lay cylinder head (1) on a suitable wooden The combustion end of cylinder head (1)
block must face upward.
8 Knock out worn valve guides (2) from the *103589021500
combustion end of cylinder head (1) using
staged drift (6)
9 Measure valve guides (2) and bores in AR05.30-W-3731-09G
cylinder head (1)
*BE05.30-N-1004-02C
*BE05.30-N-1005-02C
Cylinder brush *000589106800
Dial indicator *001589532100
Install
10 Turn the cylinder head (1) and place it on The combustion end of the cylinder head
suitable support blocks (1) must face downward.
11 Ream the valve guide bores (2) in the Only if valve guides (2) at the next
cylinder head (1) to the next oversize using oversize are to be installed.
the corresponding reamer (7)
Note the oversize of the bore diameter in *BE05.30-N-1005-02C
cylinder head (A).
For 0.2 mm oversize use reamer (7) with Ø
15.2 mm H7, and for oversize 0.4 mm use
reamer (7) with Ø 15.4 mm H7. Only turn
reamer (7) clockwise.
12 Allocate new valve guides (2) to the bores Allocate only the modified valve guides
in cylinder head (1), and mark them (2).
Valve stem seal and valve guide modified As of engine end no. 513886 BT05.30-W-0001-02G
Danger! Risk of injury when handling solid carbon Wear heat protective gloves, protective AS00.00-Z-0029-01A
dioxide (dry ice) caused by touching clothing and full eye protection.
extremely cold objects or by inhaling Ensure that the work area is adequately
gaseous carbon dioxide ventilated.
13 Pour solid carbon dioxide (dry ice) into the The valve guides (2) must be completely
cooling box, and insert new valve guides (2) covered by the solid carbon dioxide (dry ice).
using tongs Supercool the valve guides (2) in this way
for about 20 to 30 min.
*346589006300
Danger! Risk of injury when handling solid carbon Wear heat protective gloves, protective AS00.00-Z-0029-01A
dioxide (dry ice) caused by touching clothing and full eye protection.
extremely cold objects or by inhaling Ensure that the work area is adequately
gaseous carbon dioxide ventilated.
14 Take valve guide (2) out of the cooling box Observe the markings on the valve
using the tongs, push sleeve (9) over valve guides (2) and their assignments to the
guide (2) and knock valve guide (2) into bores in cylinder head (1).
cylinder head (1) using drift (8)
The gap (D) from the top edge of valve *BE05.30-N-1007-02C
guide (2) to the contact surface of the valve
spring is specified according to the
installation position of sleeve (9).
Valve guide overlap in cylinder head *BE05.30-N-1002-02C
*541589004300
15 Remove drift (8) and sleeve (9)
16 Ream the bore in valve guide (2) in stages Use an adjustable reamer (10) with Ø 8.4
using adjustable reamer (10), until reamer to 9.0 mm. Only turn reamer (10) clockwise.
(11) can be set at the bore in valve guide
(2)
17 Ream the bore in valve guide (2) to the Only turn reamer (11) clockwise. *BE05.30-N-1001-02C
inside diameter (B) using reamer (11)
*000589105300
18 Clean valve guides (2) using a cylinder *000589106800
brush (4)

© Daimler AG, 10/28/09, G/09/09 / ar05.30-w-3731g / Check, remove/install valve guides Page 2/3
ENGINE 541.9 in MODEL 930, 932, 933, 934 ENGINE 542.9 in MODEL 930, 932, 934
19 To test them, lubricate the valve stems with If used valves are being reinstalled, the
engine oil and push the valves into valve markings made on cylinder head (1) and on
guides (2) the valves must be observed.
The valve stems must make smooth contact
all round the inside of the valve guides (2).
20 Insert support disks (5)
21 Install valves AR05.30-W-3511G
22 Install cylinder head (1) AR01.30-W-5800G
23 Install nozzle holder combination AR07.03-W-6831G

Test values for valve guides

Number Designation Engine 541.9,

542.9

BE05.30-N-1001-02C Inside Ø pressed in Default mm 9.000 to 9.022

Wear limit mm 9.050

BE05.30-N-1002-02C Valve guide overlap in cylinder head mm 0.010 to 0.046

BE05.30-N-1004-02C Outside Ø Default mm 15.028 to 15.046

Oversize 0.2 mm 15.228 to 15.246

Deviation 0.4 mm 15.428 to 15.446

BE05.30-N-1005-02C Bore Ø in cylinder head Default mm 15.000 to 15.018

Oversize 0.2 mm 15.200 to 15.218

Deviation 0.4 mm 15.400 to 15.418

BE05.30-N-1007-02C Distance of top edge of valve guide to Inlet mm 19.65 to 20.95

contact surface of valve spring

Outlet mm 19.65 to 20.95

000 589 10 53 00 000 589 10 68 00 001 589 53 21 00 103 589 02 15 00

Reamer Cylinder brush Dial indicator Stepped driver

117 589 03 23 00 346 589 00 63 00 541 589 00 43 00

Drift Cooling box Drift with bushing

© Daimler AG, 10/28/09, G/09/09 / ar05.30-w-3731g / Check, remove/install valve guides Page 3/3
ENGINE 541.9 in MODEL 930, 932, 933, 934 ENGINE 542.9 in MODEL 930, 932, 934