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Cylinder Head Installation

WARNING: This page is about a different car, the 2004 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Installation should follow the removal procedure in the reverse order.
  2. Clean the contact surfaces between the cylinder head and the cylinder block.
  3. Install the dowel pin.
    4. Fig 1: Installing Dowel Pin
    G01985704Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply the liquid gasket (Loctite® 5900-M8585) on the surface of the cylinder block as described in the illustration.
  5. Install the cylinder head gasket.
  6. Apply the liquid gasket (Loctite® 5900-M8585) on the upper surface of the cylinder head gasket as described in the illustration
    7. Fig 2: Applying Liquid Gasket On Upper Surface Of Cylinder Head Gasket
    G01985705Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the cylinder head. Tighten the cylinder head bolts from center to outer as is described in the illustration.

    Tighten 

    1. Tighten the cylinder head bolts to 20 N.m (15 lb-ft). After finishing the initial tightening, tighten all the cylinder head bolts to 25 N.m (18 lb-ft) and turn the bolts another two (2) turns of 70°.
    8. Fig 3: Installing Cylinder Head
    G01985706Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the coolant outlet port.

    Tighten 

    1. Tighten the coolant outlet port retaining bolts to 8-12 N.m (71-106 lb-in).
  9. Install the ECTS (Engine Coolant Temperature Sensor). Refer to ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION .
  10. Install the CMP (Camshaft Position) sensor. Refer to CAMSHAFT POSITION (CMP) SENSOR INSTALLATION .
  11. Discard used exhaust manifold gasket and replace with a new one.
  12. Install the exhaust manifold. Refer to EXHAUST MANIFOLD INSTALLATION .
  13. Install the heater pipe.
    14. Fig 4: Installing Heater Pipe
    G01985707Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the EGR adapter.

    Tighten 

    1. Tighten the EGR adapter retaining bolts to 18-22 N.m (13-16 lb-ft).
  15. Install the EGR pipes. Refer to INTAKE EGR PIPE INSTALLATION and EXHAUST EGR PIPE INSTALLATION .
  16. Install the EGR valve. Refer to EXHAUST GAS RECIRCULATION (EGR) VALVE INSTALLATION .
    17. Fig 5: Installing EGR Valve
    G01985708Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the upper pad bracket.

    Tighten 

    1. Tighten the upper pad bracket bolts to 35-55 N.m (26-41 lb-ft).
  18. Install the alternator. Refer to GENERATOR .
    19. Fig 6: Installing Alternator
    G01985709Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the power steering pump.

    Tighten 

    1. Tighten the power steering pump retaining bolts to 20-30 N.m (15-22 lb-ft).
    20. Fig 7: Installing Power Steering Pump
    G01985710Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the intake manifold support bracket.

    Tighten 

    1. Tighten the intake manifold support bracket bolt to 20-30 N.m (15-22 lb-ft).
    21. Fig 8: Installing Intake Manifold Support Bracket
    G01985711Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the timing chain and the timing chain cover. Refer to Timing Chain Installation  .
  22. Install the cylinder head cover. Refer to Cylinder Head Cover Installation  .
  23. Install the oil pan. Refer to Oil Pan / Oil Pump Installation  .
  24. Install the engine assembly. Refer to Engine Assembly Installation  .
Fig 9: Installing Engine Assembly
G01985712Courtesy of SUZUKI OF AMERICA CORP.
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