Valve Guide: Service and Repair
NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.
REMOVAL/INSPECTING VALVE GUIDES
1. Remove cylinder head. [1][2]Procedures
2. Remove valves. [1][2]Procedures
3. Knock out valve guide as follows:
- Place cylinder head on supports tool No. 606 589 00 31 00, or equivalent.
- Use drift (01) tool No. 606 589 00 15 00 for 6 mm guides or tool No. 111 589 02 15 00 for 07 mm guides, or equivalents, to knock out valve guides (54) from the combustion chamber end
4. Measure valve guide outer Diameter
- Use a micrometer to measure and to determine which valve guide was installed; install next larger valve guide corresponding to valve guide installed; for this purpose
- Refer to the table below for specifications
Valve Guide Specifications
Guide Basic Bore In Cylinder Head:
Standard Size: 12.50-12.51 mm
Standard Size 1: 12.53 mm
Repair Size 1: 12.70 mm
Valve Guide Outer Diameter:
Standard Size: 12.54-12.55 mm
Standard Size 1 (Colored Gray): 12.56-12.57 mm
Repair Size 1 (Colored Red): 12.74-12.75 mm
Valve Guide Inner Diameter:
Inlet Valve: 6.000-6.015 mm
Exhaust Valve: 7.000-7.015 mm
Valve Guide Length (Dimension L): 37.5 mm
Valve Guide Material:
Inlet Valve: Sintered Metal
Exhaust Valve: Gray Cast Iron
Valve Guide Insertion Depth (Dimension c): 10.20-10.40 mm
5. Ream basic bore to standard size 1 or Broach basic bore to repair size 1 as required as follows:
Ream To Standard Size 1
- Place cylinder head (1) on the supports (02) 606 589 00 31 00, or equivalent.
- Ream basic bore with reamer (05) 119 589 00 53 00, to standard size 1.
Lubricate with petroleum jelly when performing this step.
Use only slight pressure for reaming and do not tilt reamer (05).
Clean blades of reamer before each reaming operation.
Broach To Repair Size 1
- Use bolts part no. 606 016 03 71 to bolt camshaft housing (2) to cylinder head.
- Place cylinder head on supports (02) 606 589 00 31 00.
- Insert guide sleeve (06) 119 589 05 63 00 together with broaching tool (05) 119 589 01 53 00 into basic bore of bucket tappet.
- Press broaching tool (05) through.
Lubricate with petroleum jelly when performing this step.
Clean broaching tool (05) with compressed air or plastic brush after each broaching operation.
Use a suitable aluminum drift as an extension in order to press through the broaching tool (05) in the area of the guide sleeve (06).
NOTE:
^ Standard size valve guides are not supplied as replacement parts
^ The press fit which would exist after guide removal would not be sufficient when they are installed.
INSTALLATION
- Insert valve guides as follows:
a. Use two bolts 606 016 03 71, or equivalent, to bolt camshaft housing (2) to cylinder head (1).
b. Place cylinder head (1) onto the supports (02) 606 589 00 31 00.
c. Moisten outside of valve guides (54) with engine oil.
d. Use insertion drift (01) to knock in valve guides (54).
Inlet, 6 mm insertion drift 606 589 01 15 00, or equivalent.
Exhaust, 7 mm insertion drift 606 589 02 15 00, or equivalent.
NOTE:
^ It is not necessary to heat the cylinder head (1) or to cool the valve guides (54).
^ The circlip at the valve guides has been discontinued since 11/94.
^ The insertion depth is fixed by the insertion drift.
e. Examine valve guides for signs of burrs and remove with reamer, necessary.
Intake, reamer 6 mm 606 589 00 53 00, or equivalent.
Exhaust, reamer 7 mm 102 589 01 53 00, or equivalent.
f. Examine insertion depth (c) of the valve guide (54), adjust to correct insertion depth if necessary.
g. Clean valve guides with cylinder brush 000 589 10 68 00, or equivalent.
- Install remaining components in the reverse order, noting the following
Examine concentricity of valve seat; machine if necessary, refer to Refinish. Service and Repair