55125-95500 Suzuki ZINC ANODE

Fig. 1-Cylinder Head to Valve Head DistanceCylinder head to intake valve head distance (new) (1, Fig. 1) ... 0.037 0.007 inch(0.94 0.18 mm)Cylinder head to exhaust valve head distance (new) (2) ... 0.057 0.007 inch(1.45 0.18 mm)Disassembly
Fig. 2-Valve RemovalUsing a valve spring compressor, compress valve springs far enough to remove retainer locks.Release spring tension and remove valve spring cap (or rotator, if so equipped) and valve spring. Mark each part so that it can be reassembled in the same position it was removed from.Remove valves, marking them for reassembly.Repair
Fig. 3-Cylinder Head FlatnessMeasure cylinder head flatness (Fig. 3).Cylinder head flatness (maximum warp) ... 0.002 inch(0.05 mm)
Fig. 4-Cylinder Head ThicknessMeasure cylinder head thickness (Fig. 4), to see if cylinder head can be resurfaced.New cylinder head thickness ... 4.134 0.005 inch(105.00 0.13 mm)Minimum cylinder head thickness ... 4.104 inch(104.24)If cylinder head thickness is less than the minimum allowable thickness, do not resurface it. Install a new cylinder head.If cylinder head is thick enough to be resurfaced, remove only enough material to remove damage. Do not resurface cylinder head if its thickness will be less than the minimum allowable after resurfacing.
Fig. 5-Valve Face AngleIf necessary to resurface valve face, grind valve face at following angle (Fig. 5):
Fig. 6-Valve Seat AngleIf necessary to resurface valve seat, grind valve seat at following angle (Fig. 6):
Fig. 7-Valve Seat WidthWhen resurfacing valve seats, the valve seat width must be maintained (Fig. 7).
Fig. 8-Valve Seat Run-OutWhen resurfacing valve seats, the valve seat run-out must be maintained (Fig. 8).Valve seat run-out (maximum) ... 0.002 inch(0.05 mm)
Fig. 9-JDE-77 or JDE-87 Valve Seat PullerUse JDE-77A Valve Seat Puller to remove intake valve seat inserts or JDE-87 Valve Seat Puller to remove exhaust valve seat inserts if they must be replaced on 4276D, 6414D, or 6414T engine.Use JDE41296 Valve Seat Puller to remove valve seat inserts if they must be replaced on 4239D, 4239T, 6359D, or 6359T engine.
Fig. 10-JDE-7 Driver and JDE-86 or JD-287 Valve Seat InstallerUse JDE-7 Driver (1, Fig. 10) with JDE-86 valve seat installer (2) (for exhaust) and JD-287 valve seat installer (2) (for intake) to install valve seat inserts. Chill the valve seat installer and valve seat insert to -20°F (-29°C) before driving into cylinder head.Grind valve seats to obtain correct cylinder head deck to valve head distance.
Fig. 11-Valve Stem Oil ClearanceMeasure valve stem oil clearance (Fig. 11).Valve stem O.D. (new) (1) ... 0.372 to 0.373 inch(9.45 to 9.47 mm)Valve guide I.D. (new) (2) ... 0.375 to 0.376 inch(9.53 to 9.55 mm)Valve stem oil clearance (new) ... 0.002 to 0.004 inch(0.05 to 0.10 mm)Valve stem oil clearance (maximum) ... 0.006 inch(0.15 mm)If valve guide oil clearance is more than maximum allowable, but not more than 0.008 inch (0.20 mm), valve guides can be knurled.
Fig. 12-D20002WI Valve Guide KnurlerUse D20002WI Valve Guide Knurler (Fig. 12) as directed by manufacturer to knurl valve guides.If valve guide oil clearance is over 0.008 inch (0.20 mm), intake and exhaust valves with oversize stems are available. Valve guides can be knurled then reamed to fit oversize valve stems. Oversize valve stems are 0.003 inch (0.08 mm), 0.015 inch (0.38 mm), or 0.030 inch (0.76 mm) oversize.Inspect valve springs for rust, cracked coils, cocking, or any other damage.Measure valve spring compression.
Fig. 13-Valve Spring LengthValve spring length (1, Fig. 13) ... 1.81 in.(46.0 mm) when compressed with 54 to 62 lb. (240 to 276 N)Valve spring length (2) ... 1.36 in.(34.5 mm) when compressed with 133 to 153 lb. (592 to 681 N)Assembly
Apply AR44402, Valve Stem Lubricant, or its equivalent, to valve stems and guides. Install valves into guides from which they were removed. Valves must move freely and seat properly.
Fig. 14-Valve Spring CounterborePosition valve springs with end of spring correctly located in the machined counterbore (Fig. 14) of the cylinder head.Install spring caps or rotators, if so equipped, and new retainer locks. "Pop" each valve three or four times by tapping the end of the valve stem with a soft mallet.Installation
IMPORTANT: Be sure all tapped holes in cylinder block are clean and free of foreign matter before installing cylinder head. On 3-179D, 4-239, 4-276, 6-359, and 6-414 engines, head gasket will fit only one way. It should not be necessary to force the gasket. The dowel pins on the cylinder head will line up gasket properly.
Fig. 15-Cylinder Head GasketOn 3-164, 4-219, and 6-329 engines, position cylinder head gasket (1, Fig. 15) over dowels on cylinder block. Check distance between cylinder head gasket and cylinder liner (2). Distance should be equal within 0.040 in. (1 mm) around each cylinder liner. If distance is not equal, make dowel holes in cylinder head gasket larger.Install cylinder head gasket dry.Set cylinder head in place on the cylinder block.Inspect cap screws for thread or under head damage. Replace as necessary. IMPORTANT: On 4-276 engine use 4.50 inch (114.3 mm) cap screws in holes 3, 6, 11, and 14 shown in Fig. 17. Use 4.25 inch (108 mm) cap screws in remaining holes. IMPORTANT: On 6-414 engine use 4.50 inch (114.3 mm) cap screws in holes 3, 6, 11, 14, 19, and 22 shown in Fig. 18. Use 4.25 inch (108 mm) cap screws in remaining holes.
Fig. 16-Three Cylinder Cylinder Head Torque Sequence
Fig. 17-Four Cylinder Cylinder Head Torque Sequence
Fig. 18-Six Cylinder Cylinder Head Torque SequenceUse hardened flat washers under all cap screws. Dip entire cap screws and washers in oil prior to installation. Start cylinder head to cylinder block cap screws by hand and tighten evenly, in several steps to 95 lb-ft (129 N m) (13 kg-m) torque following applicable sequence shown in Fig. 16, 17, or 18.Install valve stem wear caps making sure they turn freely.Install pushrods, rocker arm assembly, adjust valve clearance, and install rocker arm cover (Group 0402).Install injection nozzles and injection lines (Group 0413).Install exhaust manifold (Group 0410).Install fuel filter (Group 0420).Install water manifold or thermostat housing (Group 0418).Install air inlet piping on non-turbocharged engines (Group 0520) or