Nonferrous Metal Valve Guides

Valve Guides And Basic Bores

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

Procedures
Knocking Out Valve Guide





- Knock out valve guide (54) with drift (1) from combustion chamber side.
Removal drift 103 589 03 16 inlet dia. 8 mm
Removal drift 103 589 02 15 inlet, exhaust dia. 7 mm and 9 mm
with basic bore 13.6 mm

Measuring Valve Guide
- Measure O.D. with micrometer.
Determine which valve guide is installed.
Match up next larger valve guide, see tables above.
- Ream basic bore in cylinder head to standard size 1 or to repair size 1 depending on matched valve guide.

Standard Size 1 (Ream basic bore with reamer)





- Ream basic bore through with reamer (3).
Use reamer 104 589 00 53 00 for basic bore of 13.53 mm.

NOTE:
- Lubricate with petroleum.
- Ream with only a slight pressure and do not twist reamer (3).
- Clean blades of reamer before each reaming operation.

Repair Size 1 (Ream Basic Bore With Broaching Tool)





- Clean blades of broaching tool (8) with compressed air or plastic brush before each broaching operation.
- Insert guide sleeve (9) and broaching tool (8) into bucket tappet basic bore.
Use guide sleeve 104 589 0163 00 and broaching tool 104 589 01 53 00 for basic bore 13.70 mm.
- Press broaching tool (8) through.

NOTE:
- Lubricate with petroleum.
- Clean broaching tool (8) with compressed air after each broaching operation.

Inserting Valve Guide, Checking ID




- Supercool valve guide (54) in liquid nitrogen (about 3 minutes).
If no liquid nitrogen is available, heat cylinder head in water bath to approx. 80°C.
- Knock in valve guide (64) as far as stop (arrows) with insertion drift (7).
Insertion drift 104 589 00 15 00 inlet 0 8 mm.
Insertion drift 104 589 01 15 00 exhaust 0 9 mm.
Insertion drift 119 589 02 15 00 inlet, exhaust 0 7 mm.
- Check if valve guide (64) is tightly seated if cylinder cool.
- Check ID of valve guide (54) with gauging drift (4).
Gauging drift 102 589 00 23 00 inlet dia. 8 mm.
Gauging drift 117 589 03 23 00 exhaust dia. 9 mm.
Gauging drift 102 589 0123 00 inlet, exhaust dia. 7mm.
- It must be possible to insert fully "GO" side (6) of gauging drift (4) .
- Ream ID with reamer, it necessary.
Reamer 000 589 21 53 00 inlet dia. 8 mm.
Reamer 000 589 10 63 00 exhaust dia. 9 mm.
Reamer 102 589 01 53 00 inlet, exhaust dia. 7 mm.