Chevrolet Aveo T200 factory workshop and repair manual

Short, ordered procedure with theory and how the repair corrects faults.

Purpose and symptoms (theory)
- Valve guides locate the valve stem axially and radially so the valve seals squarely against its seat and oil does not migrate past the stem into the combustion chamber.
- Wear increases valve lateral play: causes oil burning/smoking, increased blow‑by, erratic valve seating (loss of compression, misfires), accelerated seat/face wear and valve spring misalignment.
- Repair restores concentric location and correct stem clearance so the valve rides true, seals correctly, and oil control is restored.

Ordered steps (what to do, with theory integrated)

1) Confirm fault and measure
- Symptoms: blue smoke on start/accel, oil consumption, compression or leakage past valve, visible stem wobble.
- Measure stem wobble with dial indicator on a removed valve in its guide or measure guide ID and valve stem OD with micrometer. Compare to spec. Theory: quantify excess radial clearance; guides are judged worn when clearance exceeds OEM spec.

2) Remove cylinder head and valves
- Remove head (follow torque/disassembly pattern). Remove valve springs, retainers, keep parts labeled by location. Theory: you must remove head and valves to access and machine guides accurately and maintain seat geometry.

3) Remove old guides
- Drive/punch or press out guides from combustion side (use correct driver). Heat the head moderately to expand bores if needed. Protect valve seats. Theory: guides are interference‑fit in the head; driving them out relieves worn bore so a new guide can be pressed in with correct interference.

4) Clean and inspect head bores and seats
- Clean carbon, burrs, and old material. Inspect for cracked or oversized bores and for seat damage. If the guide bores are damaged beyond repair or head is cracked, replace or machine the head. Theory: the guide must sit in solid metal and be concentric with the valve seat area; damaged bores ruin alignment.

5) Measure valve stem diameter and head bore for new guide sizing
- Measure valve stem OD at several points; measure head bore ID where guide will sit. Determine required guide inner diameter and interference fit for the new guide. Theory: final guide ID must be matched to the valve stem plus correct clearance; the guide OD must fit the head with correct interference so it remains tight through thermal cycles.

6) Select replacement guides and reamer pilots
- Use OEM or correct‑material guides (bronze or sintered steel per OEM). Get pilot reamer sized to valve stem. Theory: material choice affects wear and oil control; reamer pilot ensures reamed bore is concentric to the valve stem.

7) Install new guides
- Heat the head (or chill guides) to achieve the recommended interference fit and press the guide to the specified depth with a driver that uses the guide OD (not the bore). Verify installed depth against head datum. Theory: heating expands the head bore so the guide can be seated; cooling of the guide afterward creates the interference fit. Correct depth maintains proper distance from guide face to valve seat for spring geometry and seal position.

8) Ream the guide to final ID
- Use a pilot reamer with the correct pilot (valve stem or reamer pilot) so the reamer is guided by the valve stem axis. Cut at correct speed with cutting fluid; remove small amounts only. Theory: reaming with a pilot creates a concentric, smooth bore sized to the valve stem, restoring shaft alignment and correct radial clearance.

9) Final sizing / honing and clearance check
- After reaming, measure bore ID and check valve stem clearance. If needed, lap or use a finishing hone for very fine adjustment. Target clearance = valve stem OD subtracted from guide ID; typical passenger engines are small clearances (refer to manual; typical range is a few hundredths of a millimeter). Theory: proper radial clearance allows lubrication film without excessive wobble; too tight stalls movement and too loose causes oil control and sealing problems.

10) Fit new valve stem seals
- Install OEM seals (on guide or stem as required) with correct orientation and seating. Theory: seals prevent oil migrating down the stem; a new guide alone can reduce wear but a worn/old seal will still pass oil.

11) Reassemble valves and check seating
- Refit valves, springs, retainers; check valve to seat contact pattern. If seats were disturbed, perform valve seat refacing or lapping to reestablish full contact. Theory: guides must be concentric to seats; if seat contact is poor, sealing is compromised even with new guides.

12) Reinstall head and set valvetrain geometry
- Use new head gasket, torque head bolts in correct sequence/spec, set valve lash or preload hydraulic lifters per manual, reinstall timing. Theory: correct clamping and valve actuation geometry restores proper valve timing and lift, which is necessary for the valves to seal and perform.

13) Run-in and verify
- Warm engine, check for oil smoke, measure oil consumption, perform compression/leakdown test and listen for abnormal noise. Recheck valve clearance after initial run if applicable. Theory: reamed guides need small run‑in to bed the stem and allow lubrication film to stabilize.

How the repair fixes the fault (summary)
- Replacing/reaming guides restores correct radial location and internal diameter relative to the valve stem, eliminating excessive lateral play. This returns proper valve seating (restoring compression and preventing misfires), reduces oil migration into the combustion chamber (stops smoking and oil consumption), and prevents accelerated wear of seats and valve stems. New seals stop oil wicking past the stem. Proper interference fit of the guide keeps everything concentric through thermal cycles so the valve geometry remains stable.

Critical notes (brief)
- Use correct clearances and torque specs from the T200 service manual. Incorrect guide depth, interference, or reamer alignment will cause premature failure. Protect valve seats when removing/installing guides. Use correct tooling (press/driver, pilot reamers, dial gauges, micrometers).

Done.
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