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 Imp ton) pressure] or hammer and suitable tool.
   Fig 2: Pressing Valve Guide

   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 Using Suitable Tool

   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: Pressing Valve Guide From Camshaft Side

   Courtesy of SUZUKI OF AMERICA CORP.

   Projection "L" 

   Intake and exhaust: 12.6 - 12.8 mm (0.496 - 0.504 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: Applying Reamer Finish To Valve Guide Using Suitable Tool

   Courtesy of SUZUKI OF AMERICA CORP.

   Standard: 

   Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)