Suzuki Grand Vitara JB416 / JB420. Manual - part 91

1D-32 Engine Mechanical: For M16A Engine with VVT

Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any malcondition is found, replace.

Measure cylinder head bore and tappet outside diameter to determine cylinder head-to-tappet clearance. If clearance 
exceeds limit, replace tappet or cylinder head.

Cylinder head to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.026 in.)
Limit: 0.15 mm (0.0059 in.)

Tappet outside diameter [A]
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.)

Cylinder head tappet bore [B]
Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)

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Engine Mechanical: For M16A Engine with VVT 1D-33

Valves and Cylinder Head Components

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1. Valve cotters

7. Exhaust valve

13. Cylinder head bolt (M8)

: Be sure to tighten cylinder head bolt (M8) after 
securing the other cylinder head bolt (M10).

2. Valve spring retainer

8. Valve guide

: Tighten 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N⋅m (4.0 

kgf-m, 29.0 lb-ft), 60

° and 60° by the specified 

procedure.

3. Valve spring

 9. Cylinder head bolt (M10)

: Check cylinder head bolt (M10), plastic deformation 
tightening bolt, for deformation referring to “Cylinder Head 
Bolt” under “Valves and Valve Guides Inspection: For 
M16A Engine with VVT”, if it is reused.

: 25  N

⋅m (2.5 kgf-m, 18.0 lb-ft)

4. Valve stem seal

10. Cylinder head

: Do not reuse.

5. Valve spring seat

11. Cylinder head gasket

: “TOP” mark provided on gasket comes to crankshaft 
pulley side, facing up.

: Apply engine oil to sliding surface of each part.

6. Intake valve

12. Knock pin

1D-34 Engine Mechanical: For M16A Engine with VVT

Valves and Cylinder Head Removal and 
Installation

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Removal

1) Remove engine assembly from vehicle referring to 

“Engine Assembly Removal and Installation: For 
M16A Engine with VVT”.

2) Remove oil pan referring to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For M16A Engine 
with VVT in Section 1E”.

3) Remove cylinder head cover referring to “Cylinder 

Head Cover Removal and Installation: For M16A 
Engine with VVT”.

4) Remove timing chain cover referring to Steps 3) to 

13) of “Removal” in “Timing Chain Cover Removal 
and Installation: For M16A Engine with VVT”.

5) Remove timing chain referring to Steps 2) to 6) of 

“Removal” in “Timing Chain and Chain Tensioner 
Removal and Installation: For M16A Engine with 
VVT”.

6) Remove intake and exhaust camshafts referring to 

Steps 3) to 8) of “Removal” in “Camshaft, Tappet and 
Shim Removal and Installation: For M16A Engine 
with VVT”.

7) Loosen cylinder head bolts in such order as 

indicated in the figure by using a 12 corner socket 
wrenches and remove them.

NOTE
Don’t forget to remove bolt (M8) (1) as shown 
in the figure.

 

8) Check all around cylinder head for any other parts 

required to be removed or disconnected and remove 
or disconnect whatever necessary.

9) Remove exhaust manifold referring to “Exhaust 

Manifold Removal and Installation (For M16 Engine 
Model) in Section 1K”, if necessary.

10) Remove cylinder head with intake manifold and 

exhaust manifold. Use lifting device, if necessary.

Installation

1) Clean mating surface of cylinder head and cylinder 

block. Remove oil, old gasket and dust from mating 
surface.

2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block. 

“Top” mark or “Triangle/circle” provided on gasket 
comes to crankshaft pulley side, facing up (toward 
cylinder head side).

4) Make sure that oil jet (venturi plug) (1) is not 

clogged. If it is not installed, install it as specified 
torque.

Tightening torque
Venturi plug (a):  5 N·m (0.5 kgf-m, 3.5 lb-ft)

5) Install cylinder head to cylinder block.

Apply engine oil to new cylinder head bolts and 
tighten them gradually as follows.

NOTE
If cylinder head bolt (M10) is reused, make 
sure to check cylinder head bolt (M10) for 
deformation referring to “Cylinder Head Bolt” 
under “Cylinder Head Inspection: For M16A 
Engine with VVT”.

 

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Engine Mechanical: For M16A Engine with VVT 1D-35

a) Tighten cylinder head bolts (“1” – “10”) to 20 N

⋅m 

(2.0 kgf-m, 14.5 lb-ft) according to numerical 
order as shown by using a 12 corner socket 
wrenches.

b) In the same manner as in Step a), tighten them 

to 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft).

c) Turn all bolts 60

° according to numerical order in 

the figure.

d) Repeat Step c).
e) Tighten bolt “A” to specified torque.

NOTE
Be sure to tighten M8 bolt “A” after securing 
the other bolts.

 

Tightening torque
Cylinder head bolt for M8 (a):  25 N·m (2.5 
kgf-m, 18.0 lb-ft)
Cylinder head bolt for M10 (b):  20 N

⋅m (2.0 

kgf-m, 14.5 lb-ft), 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft) 

and then retighten by turning through to 60

° 

twice

6) Install camshafts, tappet and shim referring to 

“Camshaft, Tappet and Shim Removal and 
Installation: For M16A Engine with VVT”.

7) Install timing chain referring to “Timing Chain and 

Chain Tensioner Removal and Installation: For M16A 
Engine with VVT”.

8) Install timing chain cover referring to “Timing Chain 

Cover Removal and Installation: For M16A Engine 
with VVT”.

9) Install cylinder head cover referring to “Cylinder 

Head Cover Removal and Installation: For M16A 
Engine with VVT”.

10) Install oil pan referring to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For M16A Engine 
with VVT in Section 1E”.

Valves and Cylinder Head Disassembly and 
Assembly

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Disassembly

1) For ease in servicing cylinder head, remove intake 

manifold, injectors, exhaust manifold from cylinder 
head.

2) Using special tools (Valve lifter), compress valve 

spring and then remove valve cotters (1) also by 
using special tool (Forceps).

Special tool
(A):  09916–14510
(B):  09916–14521
(C):  09916–84511

3) Release special tools (Valve lifter), and remove 

spring retainer and valve spring.

4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and 

valve spring seat (2).

NOTE
Do not reuse valve stem seal once 
disassembled. Be sure to use new seal when 
assembling.

 

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