Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 144

1D-102 Engine Mechanical: For J20 Engine

Valves and Cylinder Head Disassembly and
Assembly

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Disassembly

1) When servicing cylinder head, remove intake

manifold, injectors, exhaust manifold and water
outlet cap from cylinder head.

2) Using special tools, compress valve springs and

then remove valve cotters (1) also by using special
tool.

Special tool
(A): 09916–14510
(B): 09916–16510
(C): 09919–28610
(D): 09916–84511

3) Release special tool, and remove spring retainers

and valve springs.

4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide, and

then valve spring seat (2).

NOTE
Do not reuse seal once disassembled. Be
sure to use new seal when assembling.

6) Using special tool (Valve guide remover), drive valve

guide out from combustion chamber side to valve
spring side.

Special tool
(A): 09916–46020

NOTE
Do not reuse valve guide once disassembled.
Be sure to use new valve guide (oversize)
when assembling.

7) Place disassembled parts except valve stem seal

and valve guide in order so that they can be installed
in their original positions.

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Engine Mechanical: For J20 Engine 1D-103

Assembly

1) Before installing valve guide into cylinder head, ream

guide hole with special tool (11 mm reamer) so as to
remove burrs and make it truly round.

Special tool
(A): 09916–34542
(B): 09916–38210

2) Install valve guide to cylinder head.

Heat cylinder head uniformly at a temperature of 80
to 100

°C (176 to 212 °F) so that head will not be

distorted, and drive new valve guide into hole with
special tools.
Drive in new valve guide until special tool (Valve
guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes
by 13.0 mm (0.51 in.) from cylinder head.

Special tool
(A): 09916–57350
(B): 09916–57340

NOTE

• Do not reuse valve guide once

disassembled. Install new valve guide
(Oversize).

• Intake and exhaust valve guides are

identical.

Valve guide oversize
0.03 mm (0.0012 in.)

Valve guide protrusion “a” (In and Ex)
13.0 mm (0.51 in.)

3) Ream valve guide bore with special tool (6.0 mm

reamer). After reaming, clean bore.

Special tool
(A): 09916–34542
(B): 09916–37810

4) Install valve spring seat to cylinder head.
5) Install new valve stem seal (1) to valve guide.

After applying engine oil to seal and spindle of
special tool (Valve guide installer handle), fit oil seal
to spindle, and then install seal to valve guide by
pushing special tool by hand.
After installing, check to be sure that seal is properly
fixed to valve guide.

Special tool
(A): 09917–98221
(B): 09916–57350

NOTE

• Do not reuse seal once disassembled. Be

sure to install new seal.

• When installing, never tap or hit special

tool with a hammer or else. Install seal to
guide only by pushing special tool by
hand. Tapping or hitting special tool may
cause damage to seal.

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1D-104 Engine Mechanical: For J20 Engine

6) Install valve to valve guide.

Before installing valve to valve guide, apply engine
oil to stem seal, valve guide bore, and valve stem.

7) Install valve spring and spring retainer.

Each valve spring has top end (large-pitch end (1))
and bottom end (small-pitch end (2)). Be sure to
position spring in place with its bottom end (small-
pitch end) facing the bottom (valve spring seat side).

8) Using special tool (Valve lifter), compress valve

spring and fit two valve cotters (1) into groove in
valve stem.

Special tool
(A): 09916–14510
(B): 09916–16510
(C): 09919–28610
(D): 09916–84511

9) Install intake manifold referring to “Intake Manifold

Removal and Installation: For J20 Engine”.

10) Install exhaust manifold referring to “Exhaust

Manifold Removal and Installation (For J20 Engine
Model): For Petrol Engine Model in Section 1K”.

11) Install injectors referring to “Fuel Injector Removal

and Installation: For Petrol Engine Model in Section
1G”.

A: Valve spring retainer side

B: Valve spring seat side

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Engine Mechanical: For J20 Engine 1D-105

Valves and Valve Guides Inspection

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Valve Guide
Valve stem-to-guide clearance
Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide
clearance.
Be sure to take reading at more than one place along the length of each stem and guide.
If clearance exceeds limit, replace valve and valve guide.

Valve stem and valve guide specification

Valve stem end deflection
If bore gauge is not available, check end deflection of valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.

Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.)

Item

Standard

Limit

Valve stem diameter [A]

In

5.965 – 5.980 mm (0.2348 – 0.2354 in.)

—

Ex

5.940 – 5.955 mm (0.2339 – 0.2344 in.)

—

Valve guide bore [B]

In & Ex

6.000 – 6.012 mm (0.2362 – 0.2366 in.)

—

Stem-to-guide clearance

In

0.020 – 0.047 mm (0.0008 – 0.0018 in.)

0.070 mm (0.0028 in.)

Ex

0.045 – 0.072 mm (0.0017 – 0.0028 in.)

0.090 mm (0.0035 in.)

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