Valve Guides

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.

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-to-guide clearance

VALVE STEM-TO-GUIDE CLEARANCE SPECIFICATION

Item		Standard	Limit
Valve stem diameter	Intake	5.965-5.980 mm (0.2348-0.2354 in.)	-
Valve stem diameter	Exhaust	5.940-5.955 mm (0.2339-0.2344 in.)	-
Valve guide bore	In and Ex	6.000-6.012 mm (0.2362-0.2367 in.)	-
Stem-to-guide clearance	Intake	0.020-0.047 mm (0.0008-0.0019 in.)	0.07 mm (0.0028 in.)
Stem-to-guide clearance	Exhaust	0.045-0.072 mm (0.0018-0.0028 in.)	0.09 mm (0.0035 in.)

Fig 1: Checking Check Stem-To-Guide Clearance

Courtesy of SUZUKI OF AMERICA CORP.

Valves

Remove all carbon from valves.
Inspect each valve for wear, burn or distortion at its face and stem and, as necessary, replace it.

Measure thickness of valve head. If measured thickness exceeds limit, replace valve.

Valve specifications

VALVE SPECIFICATIONS

Item	Standard	Limit
Intake	1.0 mm (0.039 in.)	0.6 mm (0.024 in.)
Exhaust	1.2 mm (0.047 in.)	0.7 mm (0.028 in.)

Fig 2: Identifying Valve Head Thickness

Courtesy of SUZUKI OF AMERICA CORP.

Inspect valve stem end face for pitting and wear. If pitting or wear is found, valve stem end may be resurfaced. But do not grind its taper excessively. When valve is excessively worn out too much or its taper is gone, replace it.

Fig 3: Locating Valve Stem End Face
Courtesy of SUZUKI OF AMERICA CORP.
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.)

Fig 4: Checking Radial Runout Of Valve
Courtesy of SUZUKI OF AMERICA CORP.
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 revealed by contact pattern on valve face

Intake and Exhaust: 1.1-1.3 mm (0.0433-0.0512 in.)

Fig 5: Identifying Valve Seat Face
Courtesy of SUZUKI OF AMERICA CORP.
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 figure. Two cutters must be used: the 1st for making 15° angle, and the 2nd for making 45° angle. The 2nd cut must be made to produce desired seat width.
  
  Seat width for exhaust valve seat
  
  1.1-1.3 mm (0.0433-0.0512 in.)
2. Intake valve seat
  Use valve seat cutters (1) to make three cuts as illustrated in figure. Three cutters must be used: the 1st for making 15° angle, the 2nd for making 60° angle, and the 3rd for making 45° angle. The 3rd cut (45°) must be made to produce desired seat width.
  
  Seat width for intake valve seat
  
  1.1-1.3 mm (0.0433-0.0512 in.)
  
  Fig 6: Identifying Valve Seat Cutters
  Courtesy of SUZUKI OF AMERICA CORP.
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.
  
  Fig 7: Identifying Valve Lapping Dimension
  Courtesy of SUZUKI OF AMERICA CORP.