Valves And Cylinder Heads Disassembly And Reassembly: Reassembly

Reference: VALVES AND VALVE GUIDES INSPECTION 

Reference: CYLINDER HEAD INSPECTION 

Reference: VALVE SPRINGS INSPECTION 

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 protrusions (1) by specified height 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.

   Outer diameter of oversized valve guide 

   11.088-11.103 mm (0.4365-0.4371 in.) 

   Valve guide protrusion (In and Ex) 

   13.5 mm (0.53 in.) 

   Fig 1: Reaming Guide Hole With Special Tool

   Courtesy 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

   Courtesy 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 Valve Spring Seat To Cylinder Head

     Courtesy 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: Identifying Valve

   Courtesy of SUZUKI OF AMERICA CORP.
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 (valve spring retainer side (3) facing the bottom (valve spring seat side (4).

   Fig 5: Identifying Valve Spring & Spring Retainer

   Courtesy 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. 09916-14510 
   2. 09916-14910 
   3. 09916-84511 
   4. 09919-28610 
      Fig 6: Compressing Valve Spring

      Courtesy of SUZUKI OF AMERICA CORP.