SsangYong Rexton. Manual — part 382
DIESEL ENGINE MECHANICAL 1B3-103
SSANGYONG Y200
VALVE GUIDES
Preceding Work:
Removal of cylinder head
Removal of valve spring
Removal of valve
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1 Cylinder Head
2 Valve Guide
3 Valve Seat Ring
a Basic Bore Diameter
Service Data
Intake
Exaust
Repair size 1
Repair size 2
Repair size 1
Repair size 2
14.251
14.440 - 14.451
14.240 - 14.251
14.440 - 14.451
Red
White
Red
White
0.029
- 0.051
0.029
- 0.051
14.200 - 14.211
14.400 - 14.411
14.200 - 14.211
14.400 - 14.411
8.000 - 8.030
9.000 - 9.050
39.5
37.7
Item
Outer Diameter
‘ D ’
Color Code
Overlap
‘D’ - ‘a’
Basic Bore
Diameter ‘a’
Valve Guide Inner
Diameter ‘ A ’
Length
‘ L’
SSANGYONG Y200
1B3-104 DIESEL ENGINE MECHANICAL
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Notice: Measure center (arrow) of the valve guide and
if the inner diameter ‘A’ exceeds standard value,
replace the guide.
Tools Required
000 589 10 53 00
Reamer (for Exhaust)
000 589 10 68 00
Cylinder Brush
000 589 21 53 00
Reamer (for Intake)
102 589 00 23 00
GO / NO GO Gauge (for Intake)
103 589 02 15 00
Drift (for Exhaust)
103 589 03 15 00
Drift (for Intake)
115 589 34 63 00
Mounting Device
117 589 03 23 00
GO / NO GO Gauge (for Exhaust)
346 589 00 63 00
Super Cooling Box
601 589 05 15 00
Drift (for Intake)
601 589 06 15 00
Drift (for Exhaust)
Matching Valve Seat - Broaching Tools - Guide Sleeves
Guide Sleeve Side
B
B
A
B
Valve Seat
Intake
Exhaust
Intake
Exhaust
Broaching Tool No.
115 589 00 53 00 (14.2 mm)
115 589 01 53 00 (14.4 mm)
Guide Sleeve Tool No.
102 589 00 63 00
102 589 08 63 00
601 589 15 63 00
DIESEL ENGINE MECHANICAL 1B3-105
SSANGYONG Y200
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4. Reaming basic bore in cylinder head (repair size).
- Thoroughly remove carbon deposits in cylinder
head.
Notice: Particularly remove the insides of the
valve seat rings.
- Remove the elevation (arrow) of intake valve
seat rings.
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Checking
1. Thoroughly clean the valve guide bore using a
cylinder brush 000 589 10 68 00.
Replacement Procedure
1. Drive out the valve guide (2) by using a drift
(Intake: 103 589 03 15 00, Exhaust: 103 589 02 15
00) (5).
Notice: The valve guide must be driven out
upward of the cylinder head.
2. Thoroughly clean the basic bore by using a
cylinder brush 000 589 10 68 00.
3. Check the basic bore in cylinder head for scoring
marks and ream to next repair size if necessary.
2. Insert the GO/NO GO gauge (Intake: 102 589 00
23 00, Exhaust: 117 589 03 23 00) into the valve
guide bore. If the NO GO side is inserted fully,
replace the valve guide (Intake 8 mm, Exhaust
9mm).
SSANGYONG Y200
1B3-106 DIESEL ENGINE MECHANICAL
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- Center the guide sleeve (7) in the valve seat
ring (3) by turning.
- Knock through the broaching tool (6) with a
plastic hammer (approx. 25 g) and aluminum
drift.
- Select correct broaching tool and guide sleeve
(refer to the table).
Notice: Before broaching work, the broaching
tool must be cleared of swarf with a stiff plastic
brush.
- Lubricate the basic bore, guide sleeve and
broaching tool with petroleum.
- Push broaching tool (6) in broaching direction
(arrow) into the guide sleeve (7) far enough so
that the first cut of the broaching tool is
positioned in the basic bore when guide sleeve
is fitted onto the valve seat ring (3).
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5. Heat the cylinder head (1) in a wear tank to approx.
80°C (176°F) with mounting device 115 589 34 63
00.
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6. Cool down the new valve guide (2) into the super
cooling box 346 589 00 63 00 with liquid nitrogen.
Notice: Do not touch the cooled valve guide by
hand.
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