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.