Remove/install valves - AR05.30-P-3511AV

ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220 

ENGINE 113 in MODEL 129, 163, 202, 203, 208, 209, 210, 211.076/276, 215.373/374/375, 220, 230.474/475 

ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250 

ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254 

ENGINE 113.982 in MODEL 463.243/246 

ENGINE 112.913 in MODEL 211.061/261 

ENGINE 112.949 in MODEL 211.065/265 

ENGINE 113.967 in MODEL 211.070/270 

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Remove cylinder head (1)	Model 163.154/157/172/174/175	AR01.30-P-5800MV
		Model 129 with engine 112, 113 Model 202, 208, 210 with engine 113	AR01.30-P-5800B
		Model 170, 202, 208, 210, 220 with engine 112 Model 211.076/276, 215.374, 220, 230.474/475 with engine 113	AR01.30-P-5800BA
		Model 203 except 203.764, 209, 211	AR01.30-P-5800PV
		Model 463.2 with engine 112, 113 Model 203.764 Model 215.373/375	AR01.30-P-5800GV
2	Mount cylinder head (1) onto the assembly board (2) with the associated insertion plate (3)	Insert insertion plate (3) with arrow indicating the direction of travel (insertion plate) (4) pointing to the front and, according to the cylinder head, for the right or left side into the assembly board (2). i004 Mount cylinder head (1)with its front end pointing to the arrow indicating the direction of travel (assembly board) (5) with one bolt (6) each at the front and rear onto the assembly board (2). The cylinder head (1) can be mounted on the assembly board (2) without removing the exhaust manifold. Assembly board	Fig 2
3	Attach assembly tool (valves) (7) to cylinder head (1) and position vertically at the valve disk (top) (8)	Use parts 2, 3, 4, 5, 7, 14, 19 from the valve assembly tool case (valves) (7). Valve assembly tools case	Figure
4	Remove valve disk (upper) (8) and valve disk (lower) (11)	Press valve spring (9) together with assembly tool (valves) (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 inlet valves and exhaust valves are identical.
		Magnetic pin	Fig 5
		Magnetic finger	Figure
5	Use pliers (15) to remove valve stem seals (12)	Installation:  Fit protective sleeve for valve stem seal (13) onto valve stem. Oil valve stem seal (12) and press on with drift (16). The protective sleeve for the valve stem seal (13) must be removed from the valve stem after pressing on the valve stem seal (12).
		Pliers	Figure
		Drift	Figure
6	Remove cylinder head (1) from assembly board (2)
	Risk of explosion and poisoning  caused by the melting down or improper handling of sodium-filled valves. Risk of injury  caused by skin contact with sodium resulting in heat or chemical burns.	Do not open sodium-filled valves. Wear protective gloves and safety glasses when handling damaged valves.	AS05.30-Z-0001-01A
7	Remove valve (14)	Installation:  Check surface of valve stems for roughness and formation of ridging (visual inspection or with a nail). Replace valves (14) with a rough stem surface or formation of burrs. Grind new or reused valves (14) with valve grinding compound before installation.
	Disposal of sodium-filled valves	Exhaust valves with sodium filling	OS05.30-P-0001-01A
	Checking
8	Check valves (14)	Intake and exhaust valves must not be machined. If the specified tolerances are below the required limit, the valve (14) must be replaced to ensure functioning.	AR05.30-P-4201-01AV
		Valve disk ø	*BE05.30-P-1001-01E
		Valve disk height	*BE05.30-P-1002-01E
		Valve seat angle (α)	*BE05.30-P-1003-01E
		Valve stem ø	*BE05.30-P-1004-01E
		Valve length	*BE05.30-P-1005-01E
9	Inspect valve guides, replace if necessary		AR05.30-P-3731AV
10	Install in the reverse order

Number	Designation			Engine 113.940/941/ 942/943/944	Engine 113.960/ 961/962/963/ 965/967/968/ 980/981/982/ 984/987/988/ 990/991/992/ 993/995
BE05.30-P-1001-01E	Valve disk ø	Exhaust	mm	41 ±0.1	43±0.1
		Intake	mm	36±0.1	38±0.1
BE05.30-P-1002-01E	Valve disk height	Exhaust when new	mm	1.6	1.6
		Intake when new	mm	1.2	1.2
BE05.30-P-1003-01E	Valve seat angle	(α Exhaust)	∠°	45±15'	45±15'
		Intake	∠°	45°15'	45±15'
BE05.30-P-1004-01E	Valve stem ø	Exhaust	mm	6.970	6.970
		Intake	mm	6.975	6.975
BE05.30-P-1005-01E	Valve length	Exhaust	mm	122.25±0.2	121.80±0.2
		Intake	mm	119.40±0.2	119.10±0.2

Number	Designation			Engine 112.910/911	Engine 112.912/913/ 914/915/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/948/ 949/960
BE05.30-P-1001-01E	Valve disk ø	Exhaust	mm	34±0.1	41±0.1
		Intake	mm	30±0.1	36±0.1
BE05.30-P-1002-01E	Valve disk height	Exhaust when new	mm	1.6	1.6
		Intake when new	mm	1.2	1.2
BE05.30-P-1003-01E	Valve seat angle (α)	Exhaust	∠°	45 (+15')	45 (+15')
		Intake	∠°	45 (+15')	45 (+15')
BE05.30-P-1004-01E	Valve stem ø	Exhaust	mm	6.970	6.970
		Intake	mm	6.975	6.975
BE05.30-P-1005-01E	Valve length	Exhaust	mm	121.65±0.2	122.25±
		Intake	mm	120.70±0.2	119.40±0.2