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Checking and setting the valve clearance

Checking and setting the valve clearance

(1) Exhaust valve adjusting screw (4) Lock nut

(2) Lock nut (5) EVB counter-holder lock nut
(3) Intake valve adjusting screw (6) EVB adjusting screw

Technical data
Intake valve clearance 0.5 mm
Exhaust valve clearance 0.8 mm
EVB counter-holder adjustment dimension 0.6 mm
Lock nuts (2), (4) 45 Nm
EVB counter-holder lock nut (5) 45 Nm
Cylinder head cover mounting bolts 10 Nm

Important information
WARNING
Danger of reduced engine output or engine damage
l Always adjust the valve clearance whilst the engine is cold

WARNING

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Component damage due to incorrectly tightened screw/bolt connections

l If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specified tightening torque
l Final tightening must always be performed manually using a torque wrench

Special tools
[1] 08.06450-0006 Torque wrench

Setting the valve and EVB clearance

[2] 08.75300-0000 Holding device

Checking and adjusting the valve and EVB clearance in conjunction

with:
Feeler gauge leaf 0.5
Feeler gauge leaf 0.6
Feeler gauge leaf 0.8
Valve adjusting spanner, size 14
Valve adjusting spanner, size 21
Torque wrench

[3] 80.99603-6031 Valve adjusting spanner, size 14

Adjusting the valve clearance

[4] 80.99603-6032 Valve adjusting spanner, size 21

Adjusting the EVB clearance

[5] 80.99607-0177 Feeler gauge leaf 0.5

Checking and adjusting the valve clearance

[6] 80.99607-0178 Feeler gauge leaf 0.6

Checking and adjusting the EVB clearance

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[7] 80.99607-0179 Feeler gauge leaf 0.8

Checking and adjusting the valve clearance

[8] 80.99626-6008 Engine barring gear

Cranking the engine in conjunction with:

Gear ratchet

[9] 80.99627-0001 Gear ratchet

Cranking the engine

Checking and setting the valve clearance

Removing the cable duct cover

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l Open the locking pin (2) a quarter turn

l Remove the cable duct cover (1)

Removing the cylinder head cover

Note
The mounting bolts can only be removed from the cylinder head cover with damping elements and
spacer sleeves.

l Unscrew the mounting bolts (3)

l Remove the cylinder head cover (2) from the cylinder head (1)

Attaching the engine barring gear

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l Remove the sealing cap from the flywheel housing/timing case

l Mount the Engine barring gear (1) on the flywheel housing/timing case

Moving the engine to the adjusting position

A Rocker arms in overlap B Rocker arms free

l Crank the engine in the engine's running direction using Engine barring gear and Gear ratchet until the rocker
arms are in overlap
l Adjust free rocker arms as per table

Checking the intake valve clearance

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l Insert the Holding device (4) with Feeler gauge leaf 0.5 (2) between the ball socket (1) and valve bridge (3)
Adjust the valve clearance if the valve clearance is not 0.5 mm.

Adjusting the intake valve clearance

l Undo the lock nut (2) and adjusting screw (1)

l Insert the Holding device (5) with Feeler gauge leaf 0.5 (6) between the ball socket (3) and valve bridge (4)
l Screw in the adjusting screw (1) until the Feeler gauge leaf 0.5 (6) can be moved between the ball socket (3)
and the valve bridge (4) with little resistance
l Hold the adjusting screw (1) steady with Valve adjusting spanner, size 14
l Tighten the lock nut (2) to 45 Nm using Torque wrench
l Check the setting again and, if necessary, repeat the setting procedure

Checking the exhaust valve clearance

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l Push down the valve bridge (2) several times in order to force the engine oil out of the EVB piston (5)
l Insert the Holding device (3) with Feeler gauge leaf 0.8 (4) between the ball socket (1) and valve bridge (2)
Adjust the valve clearance if the valve clearance is not 0.8 mm.

Moving the EVB piston to the adjusting position

WARNING
Danger of incorrect valve clearance
l It must be possible to fully push the EVB piston into the valve bridge

l Undo the lock nut (2) and unscrew it several turns

l Screw in the adjusting screw (1) to press the valve bridge (3) downwards several times until the stop is
reached
All the engine oil must escape from the EVB piston (4).

Adjusting the exhaust valve clearance

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l Undo the lock nut (3)

l Screw in the adjusting screw (2) to press the valve bridge (6) downwards as far as the pressure point
l Block the valve bridge (6) in this position with the adjusting screw (1)
l Insert the Holding device with Feeler gauge leaf 0.8 (5) between the ball socket (4) and valve bridge (6)
l Unscrew the adjusting screw (2) until the Feeler gauge leaf 0.8 (5) can be moved between the ball socket (4)
and the valve bridge (6) with little resistance
l Hold the adjusting screw (2) steady with Valve adjusting spanner, size 14
l Tighten the lock nut (3) to 45 Nm using Torque wrench
l Check the setting again and, if necessary, repeat the setting procedure

Checking the adjustment dimension for the EVB piston

l Lightly push down the valve bridge (1)

l Insert the Holding device (3) with Feeler gauge leaf 0.6 (2) between the counter-holder (4) and the valve bridge
(1)
Adjust the EVB clearance if the adjustment dimension is not 0.6 mm.

Adjusting the clearance for the EVB piston

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Note
The valve bridge must not move the exhaust valve when the adjusting screw is screwed in.

l Undo the lock nut (2)

l Unscrew the adjusting screw (1) until the Holding device (3) can be inserted with Feeler gauge leaf 0.6 (4)
l Screw in the adjusting screw (1) with Feeler gauge leaf 0.6 (4) inserted until the valve bridge reaches the stop
– this can be felt by a noticeable increase in force
l Hold the adjusting screw (1) steady with Valve adjusting spanner, size 21
l Tighten the lock nut (2) to 45 Nm using Torque wrench
l Check the setting again and, if necessary, repeat the setting procedure

Removing the engine barring gear

l Remove the Engine barring gear (1) from the flywheel housing/timing case
l Mount the sealing cap on the flywheel housing/timing case

Tightening sequence for cylinder head cover

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A Intake side B Exhaust side

l Stick to the illustrated mounting bolt tightening sequence 1 to 18 in the following work step

Mounting the cylinder head cover

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l Check the gasket in the cylinder head cover (2) and, if necessary, fit a new one
l Fit the cylinder head cover (2) on the cylinder head (1)
l Screw in the mounting bolts (3)
l Tighten the mounting bolts (3) to 10 Nm in the sequence indicated

Mounting the cable duct cover

l Put on the cable duct cover (1)

l Close the locking pin (2) a quarter turn

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