Replacing valve guides - RA05001192850X(05-2850)
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Preceding work:
Valve guides checked (05-2845) .
- Engine 119.960/97 with nonferrous metal valve guides VALVE GUIDES AND BASIC BORES
Engine 119.960(1) Standard size Standard size I Repair size I Basic bore in cylinder head 13.50 - 13.51 13.53 13.70 Valve guide OD and color code 13.52 - 13.53 13.52 - 13.53 grey - green 13.54 - 13.55 grey - brown 13.71 - 13.72 red Overlap 0.012 - 0.031 Inlet Exhaust Valve guide(1) ID 8.000 - 8.015 9.000 - 9.015 Length I 35.5 37.9 Dimension a 2.7 - 2.9 2.7 - 2.9 b 5.4 - 5.6 5.4 - 5.6 c 10.8 - 11.2 8.2 - 8.6 (1) Valve guides with ID inlet 8 mm and exhaust 9 mm up to engine end no. 119.960 12 011 930 Valve guides and basic bores
VALVE GUIDES AND BASIC BORESEngine 119.960(1) Engine 119.97(1) Standard size Standard size I Repair size I Basic bore in cylinder head 13.50 - 13.51 13.53 13.70 Valve guide OD and color code 13.52 - 13.53 13.52 - 13.53 grey - green 13.54 - 13.55 grey - brown 13.71 - 13.72 red Overlap 0.012 - 0.031 Inlet Exhaust Valve guide(1) ID 7.000 - 7.015 7.000 - 7.015 Length I 35.5 40.5 Dimension a 2.7 - 2.9 2.7 - 2.9 b 5.4 - 5.6 5.4 - 5.6 c 10.8 - 11.2 10.8 - 11.2 (1) Valve guide with ID 7 mm, as of engine end no. 119.960 12 011 931 up to 119.960 12 035 320 119.970 12 021 286 119.971 12 010 034 119.974 12 004 781 119.975 12 004 281 Knocking out valve guide
Valve guide (54) knock out with drift (1) from combustion chamber side.
Removal drift 103 589 03 15 inlet dia. 8 mm
Removal drift 103 589 02 15 inlet, exhaust dia. 7 mm and 9 mm with basic bore 13.5 mmMEASURING VALVE GUIDEOD measure with micrometer.
Determine which valve guide is installed. Match up next larger valve guide, see table.Basic bore in cylinder head ream to standard size I or to repair size I depending on matched valve guide. Standard size I
(Ream basic bore with reamer)
Basic bore ream 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 I
(Ream basic bore with broaching tool)
Blades of broaching tool (8) clean with compressed air or plastic brush before each broaching operation. 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 13.7 mm.Broaching tool (8) press through. NOTE: Lubricate with petroleum. Clean broaching tool (8) with compressed air after each broaching operation.Inserting valve guide, checking ID
Valve guide (54) supercool in liquid nitrogen (about 3 minutes). If no liquid nitrogen is available heat cylinder head in water bath to approx. 80 °C. Valve guide (54) knock in as far as stop (arrows) with insertion drift (7).
Insertion drift 104 589 00 15 00 inlet Ø 8 mm.
Insertion drift 104 589 01 15 00 exhaust Ø 9 mm.
Insertion drift 119 589 02 15 00 inlet, exhaust Ø 7 mm.Valve guide (54) check if tightly seated if cylinder cool. ID of valve guide (54) check 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 01 23 00 inlet, exhaust dia. 7mm.Go side (6) of gauging drift (4) ID must be possible to insert fully.
ream with reamer, if necessary.
Reamer 000 589 21 53 00 inlet dia. 8 mm.
Reamer 000 589 10 53 00 exhaust dia. 9 mm.
Reamer 102 589 01 53 00 inlet, exhaust dia. 7 mm.Special tools
Special tools
COMMERCIALLY AVAILABLE TOOLSCylinder head tensioning device e.g. Hunger
D-8000 Munchen 70
Order no. 221.60.000Micrometer 0.25 mm - Engines 119.960/97/98 with centered metal valve guides VALVE GUIDES 1) 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 OD and color code 12.54 - 12.55 12.56 - 12.57 grey 12.74 - 12.75 red Overlap 0.029 - 0.051 Inlet / Exhaust Valve guide ID 7.000 - 7.015 Length I 37.5 Dimension a - b 5.4 - 5.6 c 10.2 - 10.4 1) Sintered metal valve guides, without circlip and groove, as of engine no. 119.960 12 035 331 119.970 12 021 287 119.971 12 010 035 119.972 as of start of production 119.974 12 004 782 119.975 12 004 282 119.98 as of start of production Valve guide (54) knock out with drift (1) from combustion chamber side.
Removal drift 111 589 02 15 00 inlet, exhaust Ø 7 mm with basic bore of 12.5 mm.VALVE GUIDEOD measure with micrometer.
Determine which valve guide is installed. Match up next larger valve guide, see table.Basic bore in cylinder head ream to standard size I according to matched valve guide. or broach repair size I. Standard size I
(Ream basic bore with reamer)
Basic bore ream through with reamer (3).
Use reamer 119 589 00 53 00 for basic bore of 12.53 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 I
(Ream basic bore with broaching tool)
Blades of broaching tool (8) clean with compressed air or plastic brush before each broaching operation. Guide sleeve (9) and broaching tool (8) insert into bucket tappet basic bore.
Use guide sleeve 119 589 05 63 00 and broaching tool 119 589 01 53 00 for basic bore 12.7 mm.Broaching tool (8) press through. NOTE: Lubricate with petroleum. Clean broaching tool (8) with compressed air after each broaching operation.Inserting valve guide, checking ID
Valve guide (54) moisten on outside with oil. NOTE: It is not necessary to heat the cylinder head or to cool the valve guide (54).Valve guide (54) knock in as far as stop (arrows) with insertion drift (7).
Insertion drift 606 589 02 15 00 inlet, exhaust Ø 7 mm.NOTE: The circlip is not fitted to the centered metal valve guides. The insertion depth is fixed by the insertion drift.Installation depth (c) of valve guide (54) check, correct if necessary. Valve guide (54) clean.
Cylinder brush 000 589 10 68 00Valve guide (54) check to ensure tight. ID of valve guide (54) check with inspection drift (4).
Inspection drift 102 589 01 23 00 inlet, exhaust Ø 7mm.Go side (6) of gauging drift (4) must be possible to insert fully.
If it is not possible to insert the gauge, the valve guide should be replaced as the material of the centered metal versions is too hard for reaming.COMMERCIALLY AVAILABLE TOOLSCylinder head clamping device e.g. Hunger
D-8000 Munchen 70
Order no. 221.60.000Micrometer 0.25 mm Special tools