Cylinder Head and Valve Train Components Disassembly and Assembly: Assembly

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2008 Suzuki Reno, 2008 Suzuki Forenza, 2007 Suzuki Reno, 2007 Suzuki Forenza, and 2006 Suzuki Reno. However, it is still accessible from the selected car via links, so may be relevant.

Coat the valve stems with engine oil.
Insert the valves in the cylinder head in their original positions.
Insert the valve spring seats.
Push the accompanying assembly sleeve onto the valve stem.
Insert the new valve stem seat.
Carefully drive the valve stem seal onto the stop with light taps.
Install the valve springs in their original positions.
Install the valve spring caps.

Fig 1: Identifying Valve Spring Caps
Courtesy of SUZUKI OF AMERICA CORP.
Compress the valve springs with the valve spring compressor KM-348 and adapter KM-653.
Install the valve keys.
Remove the valve spring compressor KM-348 and adapter KM-653.

Fig 2: Removing Valve Stem Seals
Courtesy of SUZUKI OF AMERICA CORP.
Lubricate the valve tappet adjusters with engine oil.
Install the valve tappet adjusters.

Fig 3: Identifying Valve Tappet Adjusters
Courtesy of SUZUKI OF AMERICA CORP.
Install the intake camshaft.
Install the intake camshaft bearing caps in their original positions.
Install the exhaust camshaft.
Install the exhaust camshaft bearing caps in their original positions.
Install the camshaft bearing cap bolts.
Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
Tighten:

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

Fig 4: Identifying Camshaft Bearing Cap Bolts Installation Sequence
Courtesy of SUZUKI OF AMERICA CORP.
Install the spark plugs.
Tighten:

Tighten the spark plugs to 20 N.m (15 lb-ft).
Install the DIS coil and EGR mounting bracket.
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: Identifying DIS Ignition Coil And EGR Mounting Bracket And Ignition Wires
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Install the intake manifold studs.
Install the intake manifold gasket.
Install the intake manifold.
Install the intake manifold retaining nuts and retaining bolt in the sequence shown.
Tighten:

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

Fig 6: Identifying Intake Manifold Retaining Nuts And Retaining Bolt Installation Sequence
Courtesy of SUZUKI OF AMERICA CORP.
Install the fuel rail assembly. Refer to FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION .
Install the thermostat housing assembly.
Install the thermostat housing mounting bolts.
Tighten:

Tighten the thermostat housing mounting bolts to 15 N.m (11 lb-ft).
Install the coolant bypass housing and mounting bolts.
Tighten:

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

Fig 7: Identifying Coolant Bypass Housing And Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the exhaust manifold studs.
Install the exhaust manifold gasket.
Install the exhaust manifold.
Install the exhaust manifold retaining nuts in the sequence shown.
Tighten:

Tighten the exhaust manifold retaining nuts to 22 N.m (16 lb-ft).
Install the exhaust manifold heat shield.
Install the exhaust manifold heat shield bolts.
Tighten:

Tighten the exhaust manifold heat shield bolts to 8 N.m (71 lb-in).
Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION .

Fig 8: Identifying Manifold Retaining Nuts Installation Sequence
Courtesy of SUZUKI OF AMERICA CORP.