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Valves and Cylinder Heads Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2004 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 

    (E): 09916-34542 

    (F): 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 (1) by 13.5 mm (0.53 in.) from cylinder head.

    Special tool 

    (G): 09916-58210 

    (H): 09917-87810 

    NOTE:
    • Do not reuse valve guide once disassembled. Install new valve guide (Oversize).
    • Intake and exhaust valve guides are identical.

    Valve guide oversize

    11.088 - 11.103 mm (0.4366 - 0.4371 in.) 

    Valve guide protrusion (In and Ex)

    13.5 mm (0.53 in.) 

    Fig 1: Installing Valve Guide To Cylinder Head
    G02256798Courtesy of SUZUKI OF AMERICA CORP.
  3. Ream valve guide bore with special tool (6.0 mm reamer). After reaming, clean bore.

    Special tool 

    (E): 09916-34542 

    (I): 09916-37810 

    Fig 2: Reaming Valve Guide Bore With Special Tool
    G02256799Courtesy 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 

    (J): 09917-98221 

    (K): 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.
    Fig 3: Installing New Valve Stem Seal To Valve Guide
    G02256800Courtesy 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 4: Installing Valve To Valve Guide
    G02256801Courtesy of SUZUKI OF AMERICA CORP.
  7. Install valve springs (inner and outer) 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 5: Installing Valve Springs (Inner & Outer) And Spring Retainer
    G02256802Courtesy 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 

    (A): 09916-14510 

    (B): 09916-14910 

    (C): 09916-84511 

    (D): 09919-28610 

    Fig 6: Compressing Valve Spring & Fitting 2 Valve Cotter Into Groove Using Special Tool
    G02256803Courtesy of SUZUKI OF AMERICA CORP.
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