Valve Guide Replacement

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

1. To remove valve guide, heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
   Fig 1: Heating Cylinder Head

   Courtesy of SUZUKI OF AMERICA CORP.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) force] or suitable tool.
   Fig 2: Driving Out Valve Guide Using Press And Suitable Tool

   Courtesy of SUZUKI OF AMERICA CORP.
   WARNING: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
3. Ream cylinder head valve guide hole using suitable tool.
   Fig 3: Reaming Cylinder Head Valve Guide Hole

   Courtesy of SUZUKI OF AMERICA CORP.

   Valve guide hole diameter (for service parts): Intake and exhaust 

   : 10.175 - 10.196 mm (0.4006 - 0.4014 in) 

4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
   Fig 4: Heating Cylinder Head

   Courtesy of SUZUKI OF AMERICA CORP.
5. Press valve guide from camshaft side to the dimensions as shown using suitable tool.
   Fig 5: Identifying Projection For Pressing Valve Guide From Camshaft Side

   Courtesy of SUZUKI OF AMERICA CORP.

   Projection (H) 

   Intake: 10.1 - 10.3 mm (0.398 - 0.406 in) 

   Exhaust: 10.0 - 10.4 mm (0.394 - 0.409 in) 

   WARNING: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
6. Apply reamer finish to valve guide using suitable tool.
   Fig 6: Reaming Valve Guide

   Courtesy of SUZUKI OF AMERICA CORP.

   Standard Intake and exhaust: 

   6.000 - 6.018 mm (0.2362 - 0.2369 in)