Diesel Engines Cylinder Head Valve Guides

Rocker-arm geometry generates a side force, tilting the valves outward and wearing away the upper and lower ends of the guides. The loss of a sharp edge at the lower end of the guides encourages carbon buildup and accelerates stem wear; the bellmouth at the upper end catches oil, which then enters the cylinder. Figure 7-27 illustrates a split ball gauge used to determine guide ID.

Nearly all engines employ replaceable guides or, if lacking that, have enough “meat” in the casting to accept replaceable guides (Fig. 7-28). A Pep replacement guide for 0.375-in. valve stem measures 0.502 in. on the OD. The BMW 2.4L engine is one of the few for which replacement guides are not available. However, the integral (i.e., block metal) guides can be reamed to accept valves with oversized stems. The GM 350 offers the option of replaceable guides, plus oversized stems The latter are apparently a manufacturing convenience and such parts are difficult to come by.

Old guides drive out with a punch, and new guides install with a driver sized to pilot on the guide ID (Fig. 7-28). Cast-iron heads can be worked cold, but a careful technician will heat aluminum heads so that the guide bores do not gall. Engine manufacturers seem to prefer perlitic cast-iron or iron-alloy guides; many machinists claim phosphor bronze has better wearing qualities. Whatever the material, replacement guides rarely are concentric with the valve seat, and some corrective machine work is almost always in order. Stem-to-guide clearances vary with engine type and service; light- and medium-duty engines will remain oil-tight longer with a 0.0015-in. clearance. Heavy-duty engines, which run for long periods at hall rated power, need to be set up looser—as much as 0.005 in. when sodium-cooled valves are fitted.

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