Replacement of Shim

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in figure.

Fig 1: Identifying Valve Shim & Tappet
Courtesy of SUZUKI OF AMERICA CORP.
Lift down the valve by turning crankshaft to 360°.

Hold tappet at that position using special tool as follows.

Remove its housing bolts.

Check housing No. and select special tool corresponding to housing No. as below table.

Special tool selection table

CAMSHAFT HOUSING REFERENCE

No. on camshaft housing	Embossed mark on special tool
I2. I3. I4.	IN
E2. E3. E4.	EX

Fig 2: Identifying Intake & Exhaust Side Position From Timing Chain

Courtesy of SUZUKI OF AMERICA CORP.

Hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt (1) tighten housing bolts to specified torque.
Special Tool
1. 09916-66510

Tightening torque

Camshaft housing bolts a: 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified procedure

Fig 3: Identifying Camshaft Housing Bolts

Courtesy of SUZUKI OF AMERICA CORP.

Turn camshaft by approximately 90° clockwise and remove shim (3).
WARNING: Never put in the hand between camshaft and tappet.

Fig 4: Identifying Shim & Magnet
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Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table.
Shim thickness specification

Intake side:

A = B + C - 0.200 mm (0.008 in.)

Exhaust side:

A = B + C - 0.300 mm (0.012 in.)

A: Thickness of new shim

B: Thickness of removed shim

C: Measured valve clearance

Fig 5: Measuring Thickness Of Shim
Courtesy of SUZUKI OF AMERICA CORP.

For example of intake side:

When thickness of removed shim is 2.400 mm (0.094 in.), and measured valve clearance is 0.450 mm (0.018 in.).

A = 2.400 mm (0.094 in.) + 0.450 mm (0.018 in.) - 0.200 mm (0.008 in.) = 2.650 mm (0.104 in.)

Calculated thickness of new shim = 2.650 mm (0.104 in.)

Select new shim No. (1) with a thickness as close as possible to calculated value.

Available new shim No .

SHIM THICKNESS SPECIFICATION

Thickness mm (in.)	Shim No.	Thickness mm (in.)	Shim No.
2.175 (0.0856)	218	2.600 (0.1024)	260
2.200 (0.0866)	220	2.625 (0.1033)	263
2.225 (0.0876)	223	2.650 (0.1043)	265
2.250 (0.0886)	225	2.675 (0.1053)	268
2.275 (0.0896)	228	2.700 (0.1063)	270
2.300 (0.0906)	230	2.725 (0.1073)	273
2.325 (0.0915)	233	2.750 (0.1083)	275
2.350 (0.0925)	235	2.775 (0.1093)	278
2.375 (0.0935)	238	2.800 (0.1102)	280
2.400 (0.0945)	240	2.825 (0.1112)	283
2.425 (0.0955)	243	2.850 (0.1122)	285
2.450 (0.0965)	245	2.875 (0.1132)	288
2.475 (0.0974)	248	2.900 (0.1142)	290
2.500 (0.0984)	250	2.925 (0.1152)	293
2.525 (0.0994)	253	2.950 (0.1161)	295
2.550 (0.1004)	255	2.975 (0.1171)	298
2.575 (0.1014)	258	3.000 (0.1181)	300

Install new shim facing shim No. side (1) with tappet.

Fig 6: Identifying Shim Number
Courtesy of SUZUKI OF AMERICA CORP.
Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4 and remove special tool.
Special Tool
1. 09916-66510
  
  Fig 7: Identifying Tappet & Camshaft
  Courtesy of SUZUKI OF AMERICA CORP.
Install camshaft housing (1) and tighten bolts to specified torque.
Tightening torque

Camshaft housing bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Fig 8: Identifying Camshaft Housing Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Turn crankshaft pulley more than 4 rotations.
Check valve clearance again after adjusting it.
After checking and adjusting all valves.
Install cylinder head covers referring to CYLINDER HEAD COVERS REMOVAL AND INSTALLATION .