Valve Guide Replacement

Special Tools Required 

• Valve Guide Driver, 5.35 x 9.7 07742-0010100
• Valve Guide Reamer, 5.5 mm 07HAH-PJ7A100

1. Inspect valve stem-to-guide clearance (see VALVE INSPECTION  ).
2. As illustrated below, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the valve guide driver and a conventional hammer.
   Fig 1: Identifying Valve Stem-To-Guide Clearance

   
3. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for at least an hour.
4. Use a hot plate or oven to evenly heat the cylinder head to 300 °F (150 °C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300 °F (150 °C); excessive heat may loosen the valve seats.
   Fig 2: Heating Cylinder Head

   
5. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 in) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Wear safety goggles or a face shield.
6. Turn the head over, and drive the guide out toward the camshaft side of the head.
   Fig 3: Tapping Valve Guide

   
7. If a valve guide will not move, drill it out with a 8 mm (5/16 in) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks.
8. Remove the new guide(s) from the freezer, one at a time, as you need them.
9. Apply a thin coat of new engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the valve guide driver to drive the guide in to the specified installed height (A) of the guide (B). If you have all eight guides to do, you may have to reheat the head.

   Valve Guide Installed Height: 

   16.25-16.75 mm (0.640-0.659 in) 

   Fig 4: Identifying Valve Guide Installation Height

   
10. Coat both the reamer and the valve guide with cutting oil.
11. Rotate the reamer clockwise the full length of the valve guide bore.
    Fig 5: Rotating Reamer

    
12. Continue to rotate the reamer clockwise while removing it from the bore.
13. Thoroughly wash the guide in detergent and water to remove any cutting residue.
14. Check the clearances with a valve (see VALVE INSPECTION  ). Verify that a valve slides in the intake and exhaust valve guides without sticking.
15. Inspect the valve seat. If necessary renew the valve seat using a valve seat cutter (see VALVE SEAT RECONDITIONING  ).