Valve Guide: Service and Repair

Valve Guide Replacement:

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

Valve Guides And Basic Bores





Inspect valve guides.
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 And Color Coding:
Standard Size: 12.54 - 12.55 mm
Standard Size 1: 12.56 - 12.57 mm (grey)
Repair Size 1: 12.74 - 12.75 (red)
Overlap: 0.029 - 0.051 mm
Valve Guide Inner Diameter: 7.000 - 7.015 mm
Length "L": 37.5 mm
Dimension (c): 10.2 - 10.4 mm

Knocking Out Valve Guide





1. Knock out valve guide (54) with drift (1) from the combustion chamber side.
- Drift 111 589 02 15 00 for valve guide inner diameter 7 mm.
- Drift 103 589 03 15 for valve guide inner diameter 8 mm.
- Drift 103 589 02 15 for valve guide inner diameter 9 mm.
2. Measure valve guide outer diameter with micrometer. Determine which valve guide was installed; match up next larger valve guide, see table.
3. Ream basic bore in cylinder head to standard size 1 or broach repair size 1 according to matched valve guide.

Standard Size 1 (Reaming Basic Bore With Reamer)





- Ream basic bore with reamer (3)
Use reamer 104 589 00 53 00 for basic bore 013.53 mm
Use reamer 119 589 00 53 00 for basic bore 012.53 mm

NOTE:
^ Lubricate with suitable solvent when reaming.
^ Apply only slight pressure and do not tilt reamer (3).
^ Clean blades of reamer before each reaming operation.

Repair Size 1 (Broaching Basic Bore With Broaching Tool)





- Insert guide sleeve (9) and broaching tool (8) into bucket tappet basic bore. Use guide sleeve 104 589 01 63 00 and broaching tool 104 589 01 53 00 for basic bore diameter 13.7 mm. Use guide sleeve 119 589 05 63 00 and broaching tool 119 589 01 53 00 for basic bore diameter 12.7 mm.
- Press broaching tool (8) through.

NOTE:
^ Lubricate with petroleum when broaching.
^ Clean broaching tool (8) with compressed air before and after each broaching operation.

Inserting Valve Guide





1. On models with non-ferrous metal valve guides, supercool valve guides (54) in liquid nitrogen (for about 3 minutes).
- If no liquid nitrogen available, heat cylinder head in water bath to about 80° C.

2. On models with sintered metal valve guides, moisten valve guide (54) on outside with oil.

NOTE: It is not necessary to heat the cylinder head or to cool the valve guides (54).

3. On all models, knock in valve guide (54) as far as the stop (arrows) with drift (7).

NOTE: The circlip is not fitted to the sintered metal valve guides. The insertion depth is determined by the insertion drift.

- Insertion drift 119 589 02 15 00 inlet diameter 7 mm for basic bore 13.5 mm and 13.7 mm.
- Insertion drift 606 589 0215 00 inlet/exhaust diameter 7 mm for basic bore 12.5 mm and 12.7 mm.
- Insertion drift 104 589 0015 00 inlet diameter 8 mm.
- Insertion drift 104 589 02 15 00 exhaust diameter 8 mm.
- Insertion drift 104 589 01 15 00 exhaust diameter 9 mm.
4. Inspect that valve guide (54) is tight once cylinder head is cooled down.
5. Inspect inner diameter with gauging drift (4).
- Gauge 102 589 00 23 00 inlet diameter 8 mm.
- Gauge 117 589 03 23 00 exhaust diameter 9 mm.
- Gauge 102 589 01 23 00 inlet diameter 7 mm.

NOTE:
^ It must be possible to fully insert the GO side (6) of the gauge (4).
^ On models with non-ferrous metal valve guides, ream inner diameter with reamer, if necessary.
- Reamer 000 589 21 53 00 inlet diameter 8 mm.
- Reamer 000 589 10 53 00 exhaust diameter 9 mm.
- Reamer 102 589 01 53 00 inlet, exhaust diameter 7mm.
^ On models with sintered metal valve guides, if the gauge cannot be inserted, the valve guide should be replaced as the material of the sintered metal guides is too hard for reaming.