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Cylinder Head and Valve Train Components Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Coat the valve stems with engine oil.
  2. Insert the valves in the cylinder head in their original positions.
  3. Insert the valve spring seats.
  4. Push the accompanying assembly sleeve onto the valve stem.
  5. Insert the new valve stem seat.
  6. Carefully drive the valve stem seal onto the stop with light taps.
  7. Install the valve springs in their original positions.
  8. Install the valve spring caps.
    Fig 1: Installing Valve Components
    G04102784Courtesy of SUZUKI OF AMERICA CORP.
  9. Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
  10. Install the valve keys.
  11. Remove the valve spring compressor KM-348 and adapter KM-653.
    Fig 2: Removing Valve Spring Compressor
    G04102785Courtesy of SUZUKI OF AMERICA CORP.
  12. Lubricate the valve tappet adjusters with engine oil.
  13. Install the valve tappet adjusters.
    Fig 3: Installing Valve Tappet Adjusters
    G04102786Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the intake camshaft.
  15. Install the intake camshaft bearing caps in their original positions.
  16. Install the exhaust camshaft.
  17. Install the exhaust camshaft bearing caps in their original positions.
  18. Install the camshaft bearing cap bolts.
  19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown in illustration for each camshaft cap.

    Tighten 

    Tighten the camshaft bearing cap bolts to 8 N.m (71 lb-in).

    Fig 4: Tightening Camshaft Bearing Cap Bolts
    G04102787Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the spark plugs.

    Tighten 

    Tighten the spark plugs to 20 N.m (15 lb-ft).

  21. Install the DIS coil and EGR mounting bracket.
  22. Install the DIS coil and EGR mounting bracket bolts.

    Tighten 

    Tighten the direct ignition system coil and exhaust gas recirculation mounting bracket bolts to 25 N.m (18 lb-ft).

    Fig 5: Installing DIS Coil
    G04102788Courtesy of SUZUKI OF AMERICA CORP.
  23. Install the intake manifold studs.
  24. Install the intake manifold gasket.
  25. Install the intake manifold.
  26. Install the intake manifold retaining nuts and retaining bolt in the sequence shown in illustration.

    Tighten 

    Tighten the intake manifold retaining nuts and retaining bolt to 22 N.m (16 lb-ft).

    Fig 6: Installing Intake Manifold Retaining Nuts And Retaining Bolt
    G04102789Courtesy of SUZUKI OF AMERICA CORP.
  27. Install the fuel rail assembly. Refer to "FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION :".
  28. Install the thermostat housing assembly.
  29. Install the thermostat housing mounting bolts.

    Tighten 

    Tighten the thermostat housing mounting bolts to 15 N.m (11 lb-ft).

  30. Install the coolant bypass housing and mounting bolts.

    Tighten 

    Tighten the coolant bypass housing bolts to 15 N.m (11 lb-ft).

    Fig 7: Installing Thermostat Housing Mounting Bolts
    G04102790Courtesy of SUZUKI OF AMERICA CORP.
  31. Install the exhaust manifold studs.
  32. Install the exhaust manifold gasket.
  33. Install the exhaust manifold.
  34. Install the exhaust manifold retaining nuts in the sequence shown in illustration.

    Tighten 

    Tighten the exhaust manifold retaining nuts to 22 N.m (16 lb-ft).

  35. Install the exhaust manifold heat shield.
  36. Install the exhaust manifold heat shield bolts.

    Tighten 

    Tighten the exhaust manifold heat shield bolts to 8 N.m (71 lb-in).

  37. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION :".
    Fig 8: Tightening Exhaust Manifold Heat Shield Bolts
    G04102791Courtesy of SUZUKI OF AMERICA CORP.
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