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Valves And Cylinder Heads 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.
  1. Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
  2. Install knock pin (4) to cylinder block.
  3. Install new cylinder head gasket (1) to cylinder block as shown in figure. Carved lot number (5) on cylinder head gasket (1) should face up (toward cylinder head side).
    Fig 1: Identifying Head Gasket Matching Marks To Crank Shaft Pulley Side
    G04807429Courtesy of SUZUKI OF AMERICA CORP.
  4. Install cylinder head to block.

    After applying oil to cylinder head bolts, tighten them gradually as follows.

    1. Tighten cylinder head bolts (except hex hole bolt) to 53 N.m (5.3 kgf-m, 38.5 lb-ft) according to numerical order in figure.
    2. In the same manner as Step  a), tighten them to 84 N.m (8.4 kgf-m, 61.0 lb-ft).
    3. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
    4. In the same manner as Step  a), tighten them to 53 N.m (5.3 kgf-m, 38.5 lb-ft).
    5. In the same manner as Step  a) again, tighten them to 105 N.m (10.5 kgf-m, 76.0 lb-ft).
    6. Tighten cylinder head bolts (hex hole bolt) to specified torque.

      Tightening torque 

      Cylinder head bolt a: Tighten 53 N.m (5.3 kgf-m, 38.5 lb-ft), 84 N.m (8.4 kgf-m, 61.0 lb-ft), 0 N.m (0 kgf-m, 0 lb-ft), 53 N.m (5.3 kgf-m, 38.5 lb-ft) and 105 N.m (10.5 kgf-m, 76.0 lb-ft) by the specified procedure 

      Cylinder head bolt (hex hole bolt) b: Tighten 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified procedure 

      NOTE: Be sure to install hex hole bolts (1) as shown in figure.
      Fig 2: Identifying Loosening Sequence Of Camshaft Housing Bolts
      G04807430Courtesy of SUZUKI OF AMERICA CORP.
  5. Install water outlet cap.
  6. Check timing mark on crankshaft as shown in figure.
    Fig 3: Identifying Tightening Sequence Of Cylinder Head Bolts
    G04807431Courtesy of SUZUKI OF AMERICA CORP.
  7. Install tappets, shims, camshafts, and RH (No. 2) bank 2nd timing chain.

    Refer to CAMSHAFTS, TAPPETS AND SHIMS REMOVAL AND INSTALLATION AND RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION .

  8. Install 1st timing chain referring to 1ST TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION .
  9. Install LH (No. 1) bank 2nd timing chain referring to LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION .
  10. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL AND INSTALLATION .
  11. Install oil pans and oil pump strainer referring to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION .
  12. Install cylinder head covers referring to CYLINDER HEAD COVERS REMOVAL AND INSTALLATION .
  13. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION .
  14. Install radiator outlet pipe referring to COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION .
  15. Install intake manifold, intake collector and electric throttle body assembly referring to INTAKE COLLECTOR AND INTAKE MANIFOLD REMOVAL AND INSTALLATION  and ELECTRIC THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION .
  16. Install engine assembly to vehicle referring to ENGINE ASSEMBLY REMOVAL AND INSTALLATION .
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