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Home >> Suzuki >> 2007 >> Swift + >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 1.6L >> Repair Instructions >> Cylinder Head Replacement >> Installation Procedure
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Installation Procedure

  1. Assemble the cylinder head, if applicable. Refer to Cylinder Head Assemble .
    2. Fig 1: Installing Sequence Of Cylinder Head Bolts
    GM1371899Courtesy of GENERAL MOTORS CORP.
  2. Install the cylinder head gasket.
  3. Install the cylinder head with the intake manifold and the exhaust manifold attached.
  4. Install the cylinder head bolts.
    5. NOTE: Refer to Fastener Notice .
  5. Tighten the cylinder head bolts gradually and in the sequence shown.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft). Adjust the bolts to 60 degrees plus 60 degrees plus 60 degrees plus 10 degrees using J 45059  or KM-470-B  .

    6. Fig 2: View Of Heater Outlet Hose And Coolant Pipe
    GM1371896Courtesy of GENERAL MOTORS CORP.
  6. Connect the heater outlet hose to the coolant pipe.
    7. Fig 3: View Of Rear Timing Belt Cover And Bolts
    GM1371895Courtesy of GENERAL MOTORS CORP.
  7. Install the rear timing belt cover.
  8. Install the bolts to the rear timing belt cover.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    9. Fig 4: View Of CMP Sensor
    GM1371892Courtesy of GENERAL MOTORS CORP.
  9. Install the CMP sensor. Install the CMP sensor bolts.

    Tighten:  Tighten the bolts to 12 N.m (106 lb in).

    10. Fig 5: View Of Timing Belt Idler Pulley And Bolt
    GM1371894Courtesy of GENERAL MOTORS CORP.
  10. Install the timing belt idler pulley. Install the bolt. to the timing belt idler pulley

    Tighten:  Tighten the bolt to 40 N.m (30 lb ft).

    11. Fig 6: View Of Timing Belt Tensioner And Bolts
    GM1371891Courtesy of GENERAL MOTORS CORP.
  11. Install the timing belt automatic tensioner. Install the bolts to the timing belt automatic tensioner.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    12. Fig 7: View Of Intake And Exhaust Camshaft Gears
    GM1371885Courtesy of GENERAL MOTORS CORP.
    NOTE: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.
  12. Install the intake camshaft gear.
  13. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

    Tighten:  Tighten the bolt to 67.5 N.m (49 lb ft).

  14. Install the exhaust camshaft gear.
  15. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

    Tighten:  Tighten the bolt to 67.5 N.m (49 lb ft).

    16. Fig 8: View Of Valve Cover And Gasket
    GM1371857Courtesy of GENERAL MOTORS CORP.
  16. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the seal between the rear valve cover and the cylinder head.
  17. Install the valve cover and the valve cover gasket.
  18. Install the valve cover bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    19. Fig 9: Timing Marks On Camshaft Gears
    GM1750851Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the exhaust camshaft gear dowel pin is approximately in the 11 o'clock position.
  19. Align the timing marks on the camshaft gear.
    20. Fig 10: View Of Crankshaft Gear And Rear Timing Belt Cover
    GM1371900Courtesy of GENERAL MOTORS CORP.
  20. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.
    21. Fig 11: Using J42492-A Rotating Coolant Pump
    GM1371883Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
  21. Install the timing belt.
  22. Rotate the coolant pump clockwise using J 42492-A  (1), to apply tension to the timing belt.

    Tighten:  Tighten the retaining bolt to 10 N.m (89 lb in).

  23. Inspect and adjust the timing belt tension. Refer to Timing Belt Inspection .
    24. Fig 12: View Of Lower Timing Belt Cover And Bolts
    GM1371873Courtesy of GENERAL MOTORS CORP.
  24. Install the retaining bolts that secure the engine mount to the engine mount bracket.

    Tighten:  Tighten the retaining bolts to 60 N.m (44 lb ft).

  25. Install the lower front timing belt cover.
  26. Install the bolts to the lower front timing belt cover.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    27. Fig 13: View Of Balancer
    GM1371872Courtesy of GENERAL MOTORS CORP.
  27. Install the crankshaft pulley.
  28. Install the crankshaft pulley bolt.

    Tighten:  Tighten the bolt to 95 N.m (70 lb ft) using a torque wrench. Using J 45059  or KM-470-B  , tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.

    29. Fig 14: View Of Upper Front Timing Belt Cover And Bolts
    GM1371871Courtesy of GENERAL MOTORS CORP.
  29. Install the upper front timing belt cover.
  30. Install the bolts to the upper front timing belt cover.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    31. Fig 15: View Of Thermostat Housing Upper Radiator Hose
    GM1371870Courtesy of GENERAL MOTORS CORP.
  31. Connect the upper radiator hose to the thermostat housing.
  32. Connect the throttle body coolant hose to the thermostat housing.
  33. Install the catalytic converter. Refer to Catalytic Converter Replacement .
    34. Fig 16: View Of Exhaust Manifold Shield
    GM1371869Courtesy of GENERAL MOTORS CORP.
  34. Install the exhaust manifold heat shield. Install the bolts to the exhaust manifold heat shield.

    Tighten:  Tighten the bolts to 15 N.m (11 lb ft).

    35. Fig 17: View Of Intake Manifold Support Bracket
    GM1371868Courtesy of GENERAL MOTORS CORP.
  35. Connect the ECT sensor connector.
  36. Install the upper bolts to the intake manifold support bracket.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    37. Fig 18: Identifying Canister Purge Solenoid Valve
    GM1371867Courtesy of GENERAL MOTORS CORP.
  37. Install the canister purge solenoid valve at the intake manifold support bracket.
  38. Install the engine under-cover.
    39. Fig 19: Locating EGR Valve
    GM1371866Courtesy of GENERAL MOTORS CORP.
  39. Connect the front HO2S connector.
  40. Connect the EI system ignition coil connector.
  41. Connect the EGR valve connector.
    42. NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
  42. Install the accessory drive belt.
    43. Fig 20: View Of Alternator Adjusting Nut
    GM1371865Courtesy of GENERAL MOTORS CORP.
  43. Install the alternator bracket retaining nut.

    Tighten:  Tighten the nut to 25 N.m (18 lb ft).

  44. Install the alternator nut. Do NOT tighten.
    45. Fig 21: View Of Fuel Rail
    GM1371864Courtesy of GENERAL MOTORS CORP.
  45. Connect the fuel line at the fuel rail.
    46. Fig 22: Identifying Fuel Injector Harness Connectors
    GM1371863Courtesy of GENERAL MOTORS CORP.
  46. Connect the fuel injector harness connectors.
  47. Connect the ignition wires from the spark plugs.
  48. Connect the CMP sensor connector.
    49. Fig 23: Identifying Cover Screws
    GM1371851Courtesy of GENERAL MOTORS CORP.
  49. Connect the crankcase ventilation tube to the valve cover.
  50. Connect the breather tube to the valve cover.
  51. Install the engine cover.
  52. Install the engine cover bolts.
    53. Fig 24: Manifold Absolute Pressure (MAP) Sensor
    GM1371862Courtesy of GENERAL MOTORS CORP.
  53. Connect the VGIS vacuum tank hose.
  54. Connect the VGIS connector.
  55. Connect the brake booster vacuum hose.
  56. Connect the MAP sensor connector.
    57. Fig 25: View Of Throttle Body And Throttle Cable
    GM1371861Courtesy of GENERAL MOTORS CORP.
  57. Connect the engine coolant inlet/outlet hose to the throttle body.
  58. Connect the throttle cable to the throttle body and the intake manifold.
  59. Connect the TP sensor connector.
  60. Connect the IAC valve connector.
    61. Fig 26: View Of A/C Pressure Transducer (ACP) Connector
    GM1371860Courtesy of GENERAL MOTORS CORP.
  61. Connect the A/C pressure transducer connector.
    62. Fig 27: Location Of Air Cleaner
    GM1371859Courtesy of GENERAL MOTORS CORP.
  62. Install the air filter housing. Install the air filter housing bolts.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    63. Fig 28: View Of Air Intake Tube And Throttle Body
    GM1371858Courtesy of GENERAL MOTORS CORP.
  63. Connect the air intake tube to the throttle body.
  64. Connect the IAT sensor connector.
  65. Connect the breather tube to the valve cover.
  66. Install the fuel pump fuse.
  67. Connect the negative battery cable.
  68. Fill the engine cooling system. Refer to Draining and Filling Cooling System .
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