Checking and machining valves - AR05.30-P-4201HW

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 601, 602, 603 (except 602.982)

Fig 1: Inspecting Machining Valves

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing, installing
1	Remove cylinder head		AR01.30-P-5800HX
2	Remove valve springs and valve stem seals		AR05.30-D-3510-02A
			Figure
			Figure
			Figure
			Figure
3	Remove valves
	Inspecting
4	Clean valves and carry out a visual inspection	Valves with scorched valve disk, with insufficient height (h) of valve disk or with used or scored valve stem, should be replaced.	*BE05.30-P-1002-01D
5	Measure concentricity at valve stem and valve seat	if necessary replace valve	*BE05.30-P-1009-01D
	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.	AS05.30-Z-0001-01A
	Disposing of sodium-filled valves	in the case of exhaust valves with sodium filling	OS05.30-P-0001-01A *BE05.30-P-1006-01D
	Machining
6	Machine valve seat		*WE58.40-Z-1008-21A
			*BE05.30-P-1008-01D
		Pay attention to operating instructions of machining equipment and to setting angle
			*BE05.30-P-1003-01D
			*BE05.30-P-1002-01D
			*BE05.30-P-1001-01D
			*BE05.30-P-1004-01D
			*BE05.30-P-1005-01D
			*BE05.30-P-1006-01D
			*BE05.30-P-1007-01D
7	Once again measure runout at valve stem and valve seat	If runout excessive or height (h) insufficient, replace valve	*BE05.30-P-1009-01D
8	Measure valve setback to cylinder head	refer to machining cylinder head contact surface if necessary ↓	ra01006010418x
		Inspecting, removing, installing valve guides	ra05006010291x
9	Insert valve, inspect for leaks		*WH58.30-Z-1012-05A
10	Install in the reverse order

INSPECTION DATA OF VALVES

Number	Designation			Engine 601, 602.91, 603.91	Engine 602.96, 603.96
BE05.30-P-1001-01D	Valve disk dia. (D)	Exhaust	mm	34.90-35.10	34.90-35.10
		inlet	mm	37.90-38.10	37.90-38.10
		See figure		AR05.30-P-4201HW	AR05.30-P-4201HW
BE05.30-P-1002-01D	Height of valve disk (h)	Exhaust when new	mm	1.75-2.05	1.75-2.05
		Exhaust limit value	mm	1.6	1.6
		Inlet when new	mm	1.75-2.05	1.75-2.05
		Inlet limit value	mm	1.6	1.6
		See figure		AR05.30-P-4201HW	AR05.30-P-4201HW
BE05.30-P-1003-01D	Valve seat angle (α)	Exhaust	∠	45° +15'	45° +15'
		inlet	∠	45° +15'	45° +15'
		See figure		AR05.30-P-4201HW	AR05.30-P-4201HW
BE05.30-P-1004-01D	Valve stem Ø (D 1)	Exhaust	mm	8.945-8.960	8.945-8.960
		inlet	mm	7.955-7.970	7.955-7.970
		See figure		AR05.30-P-4201HW	AR05.30-P-4201HW
BE05.30-P-1005-01D	Valve seat armor plating without ==> 1 with ==> 2	Exhaust		2	2
BE05.30-P-1005-01D	Valve seat armor plating without ==> 1 with ==> 2	inlet		2	2
BE05.30-P-1006-01D	Sodium filling without ==> 1 with ==> 2	Exhaust		1	2
BE05.30-P-1006-01D	Sodium filling without ==> 1 with ==> 2	inlet		1	2
BE05.30-P-1007-01D	Length of valve (L)	Exhaust standard	mm	106.4	106.4
		Exhaust repair size	mm	105.5	105.5
		Inlet standard	mm	106.4	106.4
		Inlet repair size	mm	105.5	105.5
		See figure		AR05.30-P-4201HW	AR05.30-P-4201HW
BE05.30-P-1008-01D	Width of valve seat	Exhaust	mm	2	2
BE05.30-P-1008-01D	Width of valve seat	inlet	mm	2	2
BE05.30-P-1009-01D	Concentricity of valve seat to valve stem	Exhaust	mm	≤ 0.03	≤ 0.03
BE05.30-P-1009-01D	Concentricity of valve seat to valve stem	inlet	mm	≤ 0.03	≤ 0.03
BE05.30-P-1010-01D	Identification on end of stem	Exhaust		A 601 05	E 601 15 or E 601 17
BE05.30-P-1010-01D	Identification on end of stem	Inlet		E 601 02	A 601 19 or A 601 23

Fig 2: Identifying Pliers (606 589 00 37 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Retaining Wheel (603 589 01 40 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Assembly Board (601 589 01 59 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Valve Assembly Tool Case (111 589 25 61 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1012-05A	Vacuum testing unit

WORKSHOP EQUIPMENT

WE58.40-Z-1008-21A

Valve grinding machine