Valve Guide: Service and Repair

Replacing valve guides

Preceding work:
- Valve guides checked (052845).


Basic bore and valve guide in cylinder head








Knocking out valve guide




- Knock out valve guide (54) from combustion chamber side with drift (1).
Inlet drift 8 mm dia. 103 589 03 15
Exhaust drift 9 mm dia. 103 589 02 15


Checking basic bore, matching valve guide
- Measure OD with a micrometer.
- Determine which valve guide is installed, see table.
- Match next larger valve guide.
- File standard size I or broach repair size I basic bore in cylinder head according to matched valve guide.


Standard size I




- Ream basic bore with reamer.
- Ream through basic bore with reamer (3) 110 589 03 53 00 dia. 14.035 mm.
- Lubricate with petroleum when reaming.
- Apply only slight pressure when reaming and do not tilt reamer (3).
- Clean blades of reamer before each reaming operation.


Repair size I (broaching basic bore with broaching needle dia. 14.21)

Matching Engines - Guide Sleeves - Broaching Needles:

- Remove all carbon deposits inside of valve seat rings.
- Clean blades of broaching needle (8) with plastic brush before each broaching operation.
- Select appropriate guide sleeve (9), see table.
- Moisten guide sleeve (9), basic bore and broaching needle (8) with engine oil.
- Introduce guide sleeve (9) together with broaching needle (8) into cylinder head.
- Insert broaching needle (8) into basic bore in broaching direction up to first blade.
- Fit guide sleeve (9) onto valve seat ring (52) (arrows) and by turning center guide sleeve (9) on valve seat ring (arrows) and broaching needle (8) in basic bore.

Caution! Centering must not take place on carbon residues, casting projections, inlet and exhaust passage walls.

- Press broaching needle (8) through.


Inserting valve guide, checking ID




- Supercool valve guide (54), in liquid nitrogen (approx. 3 minutes).
- If no liquid nitrogen available, heat cylinder head in water bath to approx. 80 °C.
- Knock valve guide (54) in with drift (7) as far as stop (arrows).
Inlet drift 103 589 06 15 00.
Exhaust drift 103 589 011500.
- Check valve guide (54) when cylinder head cooled, if tightly seated.
- Check ID of valve guide (54) with gauging drift (4).
Inlet gauging drift 102589002300
Exhaust gauging drift 117 589 03 23 00
- It must be possible to insert the go side (6) of the gauging drift (4) fully.
- If necessary, ream ID with reamer.
Inlet reamer 000 589 21 53 06
Exhaust reamer 000 589 10 53 00
- Check valve seat (52) concentricity, re-work if necessary.

Special Tools:

Commercially Available Tools: