Suzuki Grand Vitara JB416 / JB420. Manual — part 92

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

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.)

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

reamer). After reaming, clean bore.

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

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

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).

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

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

NOTE
When compressing the valve spring, be
carefully to free from damage in inside face
of tappet installing hole.

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

9) Install intake manifold referring to “Intake Manifold

Removal and Installation: For M16A Engine with
VVT”.

10) Install fuel injectors referring to “Fuel Injector

Removal and Installation in Section 1G”.

11) Install exhaust manifold referring to “Exhaust

Manifold Removal and Installation (For M16 Engine
Model) in Section 1K”.

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A: Valve spring retainer side

B: Valve spring seat side

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1D-38 Engine Mechanical: For M16A Engine with VVT

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.)

Valve
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its

face and stem end, as necessary, replace it.

• Inspect valve stem end face for pitting and wear. If

pitting or wear is found there, valve stem end may be
resurfaced, but not too much to grind off its chamber.
When it is worn out too much that its chamber is gone,
replace valve.

Item

Standard

Limit

Valve stem

diameter

[A]

In

5.465 – 5.480 mm

(0.2150 – 0.2157 in.)

—

Ex

5.440 – 5.455 mm

(0.2142 – 0.2148 in.)

—

Valve guide

bore [B]

In & Ex

5.500 – 5.512 mm

(0.2165 – 0.2170 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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Engine Mechanical: For M16A Engine with VVT 1D-39

Valve head radial runout
Check each valve for radial runout with a dial gauge and
“V” block. To check runout, rotate valve slowly. If runout
exceeds its limit, replace valve.

Valve head radial runout
Limit: 0.08 mm (0.003 in.)

Seating contact width
Create contact pattern on each valve in the usual
manner, i.e., by giving uniform coat of marking
compound to valve seat and by rotatingly tapping seat
with valve head. Valve lapper (tool used in valve lapping)
must be used.
Pattern produced on seating face of valve must be a
continuous ring without any break, and the width of
pattern must be within specified range.

Standard seating width “a” revealed by contact
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0389 – 0.0551
in.)

Valve seat repair
A valve seat not producing a uniform contact with its
valve or showing width of seating contact that is out of
specified range must be repaired by regrinding or by
cutting and regrinding and finished by lapping.

1) Exhaust valve seat:

Use valve seat cutters (1) to make two cuts as
illustrated in the figure. Two cutters must be used:
the first for making 22

° angle, and the second for

making 45

° angle. The second cut must be made to

produce desired seat width.

Seat width for exhaust valve seat
“a”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)

2) Intake valve seat:

Use valve seat cutters (1) to make three cuts as
illustrated in the figure. Three cutters must be used:
the 1st for making 22

° angle, the 2nd for making 60°

angle, and 3rd for making 45

° angle. The 3rd cut

(45

°) must be made to produce desired seat width.

Seat width for intake valve seat
“b”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)

3) Valve lapping:

Lap valve on seat in two steps, first with coarse size
lapping compound applied to face and the second
with fine-size compound, each time using valve
lapper according to usual lapping method.

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