Suzuki Grand Vitara JB416 / JB420. Manual - part 109

1D-104 Engine Mechanical: For J20 Engine

3) Ream valve guide bore with special tool (6.0 mm 

reamer). After reaming, clean bore.

Special tool
(A):  09916–34542
(B):  09916–37810

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
(A):  09917–98221
(B):  09916–57350

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.

 

6) Install valve to valve guide.

Before installing valve to valve guide, apply engine 
oil to stem seal, valve guide bore, and valve stem.

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 (small-
pitch end) facing the bottom (valve spring seat side).

8) Using special tool (Valve lifter), compress valve 

spring and fit two valve cotters (1) into groove in 
valve stem.

Special tool
(A):  09916–14510
(B):  09916–16510
(C):  09919–28610
(D):  09916–84511

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A: Valve spring retainer side

B: Valve spring seat side

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Engine Mechanical: For J20 Engine 1D-105

9) Install intake manifold referring to “Intake Manifold Removal and Installation: For J20 Engine”.

10) Install exhaust manifold referring to “Exhaust Manifold Removal and Installation (For J20 Engine Model) in Section 

1K”.

11) Install injectors referring to “Fuel Injector Removal and Installation in Section 1G”.

Valves and Valve Guides Inspection

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Valve Guide
Valve stem-to-guide clearance
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 and valve guide specification

Valve stem end deflection
If bore gauge is not available, check end deflection of valve stem with a dial gauge instead.
Move stem end in directions (1) and (2) to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.

Valve stem end deflection limit
In: 0.14 mm (0.005 in.)
Ex: 0.18 mm (0.007 in.)

Item

Standard

Limit

Valve stem diameter [A]

In

5.965 – 5.980 mm (0.2348 – 0.2354 in.)

—

Ex

5.940 – 5.955 mm (0.2339 – 0.2344 in.)

—

Valve guide bore [B]

In & Ex

6.000 – 6.012 mm (0.2362 – 0.2366 in.)

—

Stem-to-guide clearance

In

0.020 – 0.047 mm (0.0008 – 0.0018 in.)

0.070 mm (0.0028 in.)

Ex

0.045 – 0.072 mm (0.0017 – 0.0028 in.)

0.090 mm (0.0035 in.)

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1D-106 Engine Mechanical: For J20 Engine

Valve
Visual inspection
• Remove all carbon from valves.
• Inspect each valve for wear, burn or distortion at its 

face and stem end, as necessary, replace it.

• Inspect valve stem end face for pitting and wear. If 

pitting or wear is found there, valve stem end may be 
resurfaced, but not too much to grind off its chamber. 
When it is worn out too much that its chamber is gone, 
replace valve.

Valve head thickness
Measure thickness “a” of valve head. If measured 
thickness exceeds limit, replace valve.

Valve head thickness “a”
Intake
Standard: 1.25 – 1.55 mm (0.049 – 0.061 in.)
Limit: 0.9 mm (0.035 in.)
Exhaust
Standard: 1.45 – 1.75 mm (0.057 – 0.069 in.)
Limit: 1.1 mm (0.04 in.)

Valve head radial runout
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.)

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 “a” revealed by contact 
pattern on valve face
Intake and Exhaust: 1.0 – 1.4 mm (0.0389 – 0.0551 
in.)

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Engine Mechanical: For J20 Engine 1D-107

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 the figure. Two cutters must be used: 
the first for making 15

° angle, and the second for 

making 45

° angle. The second cut must be made to 

produce desired seat width.

Seat width for exhaust valve seat
“a”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)

2) Intake valve seat: 

Use valve seat cutters (1) to make three cuts as 
illustrated in the figure. Three cutters must be used: 
the 1st for making 25

° angle, the 2nd for making 60° 

angle, and 3rd for making 45

° angle. The 3rd cut 

(45

°) must be made to produce desired seat width.

Seat width for intake valve seat
“b”: 1.0 – 1.4 mm (0.0389 – 0.0551 in.)

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.

Cylinder Head Inspection

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• Remove all carbon deposits from combustion 

chambers.

NOTE
Do not use any sharp-edged tool to scrape 
off carbon deposits. Be careful not to scuff or 
nick metal surfaces when decarbonizing. The 
same applies to valves and valve seats, too.

 

• Check cylinder head for cracks on intake and exhaust 

ports, combustion chambers, and head surface. Using 
a straightedge and thickness gauge, check flatness of 
gasketed surface at a total of 6 locations. If distortion 
limit is exceeded, correct gasketed surface with a 
surface plate and abrasive paper of about #400 
(Waterproof silicon carbide abrasive paper): place 
abrasive paper on and over surface plate, and rub 
gasketed surface against paper to grind off high spots. 
Should this fail to reduce thickness gauge readings to 
within limit, replace cylinder head. 
Leakage of combustion gases from this gasketed joint 
is often due to warped gasketed surface: such 
leakage results in reduced power output.

Distortion for cylinder head surface on piston side
Limit: 0.03 mm (0.001 in.)

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