Replacing valve guides - RA05001042850X(05-2850)
WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.
Preceding work:
Valve guides inspected (05-2845) .
- Non-ferrous metal valve guides, engine 104.980/981 (1st and 2nd version) and engine 104.990 (1st version) VALVE GUIDES AND BASIC BORES
Standard size Standard size I Repair size I Basic bore in cylinder head 13.50 - 13.51 13.53 13.70 Valve guide outer Ø and color coding 13.52 - 13.53 13.54 - 13.55 grey-brown 13.71 - 13.72 red Overlap 0.012 - 0.031 Inlet Exhaust Valve guides 1st version inner Ø 8.000 - 8.015 9.000 - 9.015 Valve guides 2nd version inner Ø 7.000 - 7.015 8.000 - 8.015 Length (L) 35.5 37.9 Dim. (c) 10.8 - 11.2 8.2 - 8.6 - Sintered metal valve guides engine 104.980/981 (3rd version) engine 104.990 (2nd version) engines 104.940/941/942/943/944/945/ 992/994/995/996 as of start of production VALVE GUIDES AND BASIC BORES
Standard size Standard size I Repair size I Basic bore in cylinder head 12.50 - 12.51 12.53 12.70 Valve guide outer Ø and color coding 12.54 - 12.55 12.56 - 12.57 grey 12.74 - 12.75 red Overlap 0.029 - 0.051 Inlet/Exhaust Valve guide inner Ø 7.000 - 7.015 Length (L) 37.5 Dim. (c) 10.2 - 10.4 Replacing non-ferrous metal and centered metal valve guides
Knocking out valve guide
Valve guide (54) knock out with drift (1) from the combustion chamber side.
Drift 111 589 02 15 00 for valve guide inner Ø 7 mm.
Drift 103 589 03 15 for valve guide inner Ø 8 mm.
Drift 103 589 02 15 for valve guide inner Ø 9 mm.VALVE GUIDE VALUESOuter Ø measure with micrometer.
Determine which valve guide was installed; match up next larger valve guide, see table.Basic bore in cylinder head ream standard size I or broach repair size I according to matched valve guide. Standard size I
(reaming basic bore with reamer)
Basic bore ream through with reamer (3).
Use reamer 104 589 00 53 00 for basic bore Ø 13.53 mm
Use reamer 119 589 00 53 00 for basic bore Ø 12.53 mmNOTE: Lubricate with petrol when reaming. Apply only slight pressure and do not tilt reamer (3). Clean blades of reamer before each reaming operation.Repair size I
(broaching basic bore with broaching tool)
Guide sleeve (9) and broaching tool (8) insert into bucket tappet basic bore.
Use guide sleeve 104 589 01 63 00 and broaching tool 104 589 01 53 00 for basic bore Ø 13.7 mm.
Use guide sleeve 119 589 05 63 00 and broaching tool 119 589 01 53 00 for basic bore Ø 12.7 mm.Broaching tool (8) press through. NOTE: Lubricate with petroleum when broaching. Clean broaching tool (8) with compressed air before and after each broaching operation.Inserting valve guide
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. 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).Valve guide (54) knock in as far as the stop (arrows) with drift (7).
Insertion drift 119 589 02 15 00 inlet Ø 7 mm for basic bore 13.5 and 13.7.
Insertion drift 606 589 02 15 00 inlet/exhaust Ø 7 mm for basic bore 12.5 and 12.7.
Insertion drift 104 589 00 15 00 inlet Ø 8 mm.
Insertion drift 104 589 02 15 00 exhaust Ø 8 mm.
Insertion drift 104 589 01 15 00 exhaust Ø 9 mm.NOTE: The circlip is not fitted to the centered metal valve guides. The insertion depth is determined by the insertion drift.Valve guide (54) inspect that it is tight once cylinder head is cooled down. Inner Ø of valve guide (54) inspect with gauging drift (4).
Gauge 102 589 00 23 00 inlet Ø 8 mm.
Gauge 117 589 03 23 00 exhaust Ø 9 mm.
Gauge 102 589 01 23 00 inlet Ø 7 mm.NOTE: It must be possible to fully insert the GO side (6) of the gauge (4).
Non-ferrous metal valve guides : ream inner Ø with reamer, if necessary.
Reamer 000 589 21 53 00 inlet Ø 8 mm.
Reamer 000 589 10 53 00 exhaust Ø 9 mm.
Reamer 102 589 01 53 00 inlet, exhaust Ø 7 mm.
Sintered metal valve guides : if the gauge cannot be inserted, the valve guide should be replaced as the material of the centered metal guides too hard for reaming.Special tools
Special tools
COMMERCIALLY AVAILABLE TOOLSCylinder head clamping device e.g. Hunger D-8000 Munich 70
Order no. 221.60.000Micrometer 0.25 mm