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Valves, Cylinder Head Disassembly & Assembly: Assembly

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  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 

    1. (A):  09916-34542
    2. (B):  09916-38210
    Fig 1: Reaming Valve Guide Hole
    G01351916Courtesy of SUZUKI OF AMERICA CORP.
  2. Install valve guide to cylinder head.

    Heat cylinder head uniformly to 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 (1) by 13.5 mm (0.53 in.) from cylinder head.

    Special tool 

    1. (A):  09916-58210
    2. (B):  09916-87810
    NOTE:
    • Do not reuse once-disassembled valve guide. Install new valve guide (Oversize).
    • Intake and exhaust valve guides are identical.

    Valve guide oversize 

    1. 0.03 mm (0.0012 in.)

    Valve guide protrusion (In and Ex) 

    1. 13.5 mm (0.53 in.)
    Fig 2: Installing Valve Guide
    G01351917Courtesy of SUZUKI OF AMERICA CORP.
  3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.

    Special tool 

    1. (A):  09916-34542
    2. (B):  09916-37810
    Fig 3: Reaming Valve Guide
    G01351918Courtesy of SUZUKI OF AMERICA CORP.
  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 

    1. (A):  09917-98221
    2. (B):  09916-58210
    NOTE:
    • Do not reuse once-disassembled seal. Be sure to install new seal.
    • When installing, never tap or hit special tools with a hammer or else. Install seal to guide only by pushing special tools by hand. Tapping or hitting special tools may cause damage to seal.
    Fig 4: Installing New Valve Stem Seal
    G01351919Courtesy of SUZUKI OF AMERICA CORP.
  6. Install valve (1) to valve guide.

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

    Fig 5: Installing Valve To Valve Guide
    G01351920Courtesy of SUZUKI OF AMERICA CORP.
  7. Install valve springs (inner and outer springs) 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 (valve spring retainer side (3)). facing the bottom (valve spring seat side (4)).

    Fig 6: Identifying Valve Spring Top End & Bottom End
    G01351921Courtesy of SUZUKI OF AMERICA CORP.
  8. Using special tool (Valve lifter), compress valve spring and fit 2 valve cotters (1) into groove in valve stem.

    Special tool 

    1. (A):  09916-14510
    2. (B):  09916-14910
    3. (C):  09919-28610
    4. (D):  09916-84511
    Fig 7: Installing Valve Cotters Into Groove In Valve Stem
    G01351922Courtesy of SUZUKI OF AMERICA CORP.
  9. Install intake manifold, injectors, exhaust manifold, water outlet pipe (2) and water outlet cap to cylinder head (1).
    NOTE: When installing water outlet pipe (2), apply sealant to the thread of the bolt shown in the figure.
    1. "A":  Sealant 99000-31110
    Fig 8: Identifying Water Outlet Pipe & Water Outlet Cap
    G01351923Courtesy of SUZUKI OF AMERICA CORP.
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