Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 127

1D-34 Engine Mechanical: For M16A Engine with VVT

Valves and Cylinder Head Removal and
Installation

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Removal

1) Remove engine assembly from vehicle referring to

“Engine Assembly Removal and Installation: For
M16A Engine with VVT”.

2) Remove oil pan referring to “Oil Pan and Oil Pump

Strainer Removal and Installation: For M16A Engine
with VVT in Section 1E”.

3) Remove cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For M16A
Engine with VVT”.

4) Remove timing chain cover referring to Steps 3) to

13) of “Removal” in “Timing Chain Cover Removal
and Installation: For M16A Engine with VVT”.

5) Remove timing chain referring to Steps 2) to 6) of

“Removal” in “Timing Chain and Chain Tensioner
Removal and Installation: For M16A Engine with
VVT”.

6) Remove intake and exhaust camshafts referring to

Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation: For M16A Engine
with VVT”.

7) Loosen cylinder head bolts in such order as

indicated in the figure by using a 12 corner socket
wrenches and remove them.

NOTE
Don’t forget to remove bolt (M8) (1) as shown
in the figure.

8) Check all around cylinder head for any other parts

required to be removed or disconnected and remove
or disconnect whatever necessary.

9) Remove exhaust manifold referring to “Exhaust

Manifold Removal and Installation (For M16 Engine
Model): For Petrol Engine Model in Section 1K”, if
necessary.

10) Remove cylinder head with intake manifold and

exhaust manifold. Use lifting device, if necessary.

Installation

1) Clean mating surface of cylinder head and cylinder

block. Remove oil, old gasket and dust from mating
surface.

2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.

“Top” mark or “Triangle/circle” provided on gasket
comes to crankshaft pulley side, facing up (toward
cylinder head side).

4) Make sure that oil jet (venturi plug) (1) is not

clogged. If it is not installed, install it as specified
torque.

Tightening torque
Venturi plug (a): 5 N·m (0.5 kgf-m, 3.5 lb-ft)

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Engine Mechanical: For M16A Engine with VVT 1D-35

5) Install cylinder head to cylinder block.

Apply engine oil to new cylinder head bolts and
tighten them gradually as follows.

NOTE
If cylinder head bolt (M10) is reused, make
sure to check cylinder head bolt (M10) for
deformation referring to “Cylinder Head Bolt”
under “Cylinder Head Inspection: For M16A
Engine with VVT”.

a) Tighten cylinder head bolts (“1” – “10”) to 20 N

⋅m

(2.0 kgf-m, 14.5 lb-ft) according to numerical
order as shown by using a 12 corner socket
wrenches.

b) In the same manner as in Step a), tighten them

to 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft).

c) Turn all bolts 60

° according to numerical order in

the figure.

d) Repeat Step c).
e) Tighten bolt “A” to specified torque.

NOTE
Be sure to tighten M8 bolt “A” after securing
the other bolts.

Tightening torque
Cylinder head bolt for M8 (a): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
Cylinder head bolt for M10 (b): 20 N

⋅m (2.0

kgf-m, 14.5 lb-ft), 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft)

and then retighten by turning through to 60

°

twice

6) Install camshafts, tappet and shim referring to

“Camshaft, Tappet and Shim Removal and
Installation: For M16A Engine with VVT”.

7) Install timing chain referring to “Timing Chain and

Chain Tensioner Removal and Installation: For M16A
Engine with VVT”.

8) Install timing chain cover referring to “Timing Chain

Cover Removal and Installation: For M16A Engine
with VVT”.

9) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation: For M16A
Engine with VVT”.

10) Install oil pan referring to “Oil Pan and Oil Pump

Strainer Removal and Installation: For M16A Engine
with VVT in Section 1E”.

Valves and Cylinder Head Disassembly and
Assembly

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Disassembly

1) For ease in servicing cylinder head, remove intake

manifold, injectors, exhaust manifold from cylinder
head.

2) Using special tools (Valve lifter), compress valve

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

Special tool
(A): 09916–14510
(B): 09916–14521
(C): 09916–84511

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1D-36 Engine Mechanical: For M16A Engine with VVT

3) Release special tools (Valve lifter), and remove

spring retainer and valve spring.

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

valve spring seat (2).

NOTE
Do not reuse valve stem 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): 09916–44910

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 position.

Assembly

1) Before installing valve guide into cylinder head, ream

guide hole with special tool (10.5 mm reamer) so as
to remove burrs and make it truly round.

Special tool
(A): 09916–34542
(B): 09916–37320

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 specified dimension “a” from cylinder head.

Special tool
(A): 09916–58210
(B): 09916–56011

NOTE

• Never reuse valve guide once

disassembled. Make sure to install new
valve guide (Oversize).

• Intake and exhaust valve guides are

identical.

Valve guide protrusion (In and Ex)
“a”: 11.3 mm (0.44 in.)

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Engine Mechanical: For M16A Engine with VVT 1D-37

3) Ream valve guide bore with special tool (5.5 mm

reamer). After reaming, clean bore.

Special tool
(A): 09916–34542
(B): 09916–34550

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): 09916–58210

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.

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).

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A: Valve spring retainer side

B: Valve spring seat side

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