Cylinder Head Covers Removal And Installation: Installation

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Clean sealing surfaces on cylinder heads and covers.
Remove oil, old sealant, and dust from sealing surfaces. After cleaning, apply sealant "A" to cylinder heads sealing surface area as shown in figure.
"A": Water tight sealant 99000-31250SUZUKI Bond No. 1207F

Fig 1: Identifying Area For Applying Sealant
Courtesy of SUZUKI OF AMERICA CORP.
Install new spark plug hole gaskets (3) and new cylinder head cover gaskets (2) to head covers (1).
Apply sealant "A" to cylinder head gaskets searing surface area as shown in figure.
"A": Water tight sealant 99000-31250SUZUKI Bond No. 1207F

Fig 2: Identifying Spark Plug Hole Gaskets
Courtesy of SUZUKI OF AMERICA CORP.
Install cylinder head covers (1) to cylinder heads.
Using new seal washers (3), tighten nuts (2) following sequence ("1"-"4") as indicated in figure. Tighten a little at a time and evenly among nuts and repeat tightening sequence 2 or 3 times before they are tightened to specified torque.
Tightening torque

Cylinder head cover nut a: 10.5 N.m (1.1 kg-m, 7.5 lb-ft)

Fig 3: Identifying Seal Washers & Tighten Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Install ignition coils and connect ignition coil couplers referring to IGNITION COIL ASSEMBLY (IGNITER AND IGNITION COIL) REMOVAL AND INSTALLATION .
Clamp engine harness (2) to cylinder head cover.
Install heater outlet pipe (1).

Fig 4: Identifying Engine Harness
Courtesy of SUZUKI OF AMERICA CORP.
Install intake manifold and intake collector referring to INTAKE COLLECTOR AND INTAKE MANIFOLD REMOVAL AND INSTALLATION .
Install electric throttle body assembly referring to ELECTRIC THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION .