Cylinder Head Assemble

Reference: CYLINDER HEAD CLEANING AND INSPECTION .

Reference: VALVE SPRING INSPECTION AND MEASUREMENT .

Reference: VALVE AND SEAT GRINDING .

Special Tool 

J 8062 Valve Spring Compressor - Head Off 

EN 46116 Valve Stem Seal Remover/Installer 

EN 46117 Valve Stem Key Remover/Installer 

EN 46119 Off-Vehicle Valve Spring Compressor Adapter 

Fig 1: Identifying Cylinder Head Coolant Threaded Plugs

Courtesy of SUZUKI OF AMERICA CORP.

1. Install the cylinder head coolant threaded plugs.

   Tightening torque 

   Tighten the cylinder head coolant threaded plug to 31 N.m (23 lb ft)  .

   Fig 2: Identifying Cylinder Head Oil Gallery Expansion Plugs

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2. Install the NEW cylinder head oil gallery expansion plugs.
   Fig 3: Identifying Valve Stem Oil Seals

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3. Place the valve stem oil seals onto the guides.
   NOTE: NEVER reuse a valve stem oil seal. Always use new seals when assembling the cylinder head.
4. Mount a new valve stem oil seal using the EN 46116.
   NOTE: Force should only be applied to the valve spring contact area of the new valve stem oil seal during installation.
5. Push and twist the valve stem oil seal into position on the valve guide until the seal positively locks on the guide using the EN 46116.
6. Lubricate the valve stem and valve guide ID with clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent.
   Fig 4: Identifying Valve

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   NOTE: The valve stem oil seal must not come loose from the valve guide when the valve is installed.
7. Insert the valve into the valve guide until it bottoms on the valve seat.
   Fig 5: Identifying Valve Spring & Valve Spring Retainer

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8. Position the valve spring on the spring seat.
9. Place the valve spring retainer onto the valve spring.
   Fig 6: Compressing Valve Springs

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   WARNING: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury.
   CAUTION: Do not compress the valve springs less than 24.0 mm (0.943 in). Contact between the valve spring retainer and the valve stem oil seal can cause potential valve stem oil seal damage.
10. Compress the valve spring using the J 8062 and the EN 46119.
    Fig 7: Identifying Valve Keepers

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: Ensure proper directional placement of valve keepers in the EN 46117. The valve keepers must be installed with the tapered end towards the valve stem seal.
11. With the spring compressed, install the valve keepers into the EN 46117.
    Fig 8: Compressing Valve Springs

    Courtesy of SUZUKI OF AMERICA CORP.
12. Place the keepers into position by pushing the tool downward and releasing tension on the EN 46119 and the J 8062.
13. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-blow hammer. The valve keepers and the spring should remain in place.

Reference: CYLINDER HEAD INSTALLATION - RIGHT SIDE .

Reference: CYLINDER HEAD INSTALLATION - LEFT SIDE .