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Cylinder Head and Valve Train Components Disassembly and Assembly: Disassembly

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.
  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION .
  2. Remove the exhaust manifold heat shield bolts.
  3. Remove the exhaust manifold heat shield.
  4. Remove the exhaust manifold retaining nuts in the sequence shown.
  5. Remove the exhaust manifold.
  6. Remove the exhaust manifold gasket.
  7. Remove the exhaust manifold studs.
    Fig 1: Identifying Exhaust Manifold Studs
    G04716495Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the thermostat housing mounting bolts.
  9. Remove the thermostat housing assembly.
  10. Remove the fuel rail assembly. Refer to FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION .
  11. Remove the coolant bypass housing mounting bolts and the housing.
    Fig 2: Identifying Coolant Bypass Housing Mounting Bolts And Housing
    G04716496Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the intake manifold retaining nuts and retaining bolt in the sequence shown.
  13. Remove the intake manifold.
  14. Remove the intake manifold gasket.
    Fig 3: Identifying Intake Manifold Retaining Nuts And Retaining Bolt Removal Sequence
    G04716442Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove the Direct Ignition System (DIS) coil and the Exhaust Gas Recirculation (EGR) mounting bracket bolts.
  16. Remove the DIS ignition coil and the EGR mounting bracket and ignition wires.
  17. Remove the intake manifold studs.
  18. Remove the spark plugs.
    Fig 4: Identifying DIS Ignition Coil And EGR Mounting Bracket And Ignition Wires
    G04716498Courtesy of SUZUKI OF AMERICA CORP.
  19. Remove the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.
    Fig 5: Identifying Camshaft Bearing Cap Bolt Removal Sequence
    G04716400Courtesy of SUZUKI OF AMERICA CORP.
  20. Remove the intake camshaft caps. Maintain the correct positions for installation.
  21. Remove the intake camshaft.
  22. Remove the intake valve tappet adjusters.
  23. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
  24. Remove the exhaust camshaft.
  25. Remove the exhaust valve tappet adjusters.
    Fig 6: Identifying Exhaust Camshaft Caps
    G04716500Courtesy of SUZUKI OF AMERICA CORP.
  26. Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
  27. Remove the valve retainers.
  28. Remove the valve spring compressor KM-348 and the adapter KM-653.
  29. Remove the valve spring caps.
  30. Remove the valve springs. Maintain the original position of the valve springs for installation.
    Fig 7: Removing Valve Springs
    G04716501Courtesy of SUZUKI OF AMERICA CORP.
  31. Remove the valves. Maintain the original position of the valves for installation.
  32. Remove the valve stem seals.
    Fig 8: Removing Valve Stem Seals
    G04716502Courtesy of SUZUKI OF AMERICA CORP.
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