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

    Fig 1: Locating Fuel Pump Fuse
    GM1291944Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Safety Glasses Caution .
  1. Remove the fuel pump fuse.
  2. Start the engine. Crank the engine after the engine stalls for 10 seconds to rid the fuel system of fuel pressure.
  3. Drain the engine coolant. Refer to Draining and Filling Cooling System .
    4. Fig 2: View Of Air Intake Tube And Throttle Body
    GM1371858Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the breather tube from the valve cover.
  5. Disconnect the intake air temperature (IAT) sensor connector.
  6. Disconnect the air intake tube from the throttle body.
    7. Fig 3: Location Of Air Cleaner
    GM1371859Courtesy of GENERAL MOTORS CORP.
  7. Remove the air filter housing bolts.
  8. Remove the air filter housing.
    9. Fig 4: View Of A/C Pressure Transducer (ACP) Connector
    GM1371860Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the A/C pressure (ACP) transducer connector.
    10. Fig 5: View Of Throttle Body And Throttle Cable
    GM1371861Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the idle air control (IAC) valve connector.
  11. Disconnect the throttle position (TP) sensor connector.
  12. Disconnect the throttle cable from the throttle body and the intake manifold.
  13. Disconnect the engine coolant inlet/outlet hose at the throttle body.
    14. Fig 6: Manifold Absolute Pressure (MAP) Sensor
    GM1371862Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the manifold absolute pressure (MAP) sensor connector.
  15. Disconnect the brake booster vacuum hose.
  16. Disconnect the variable geometry induction solenoid (VGIS) connector.
  17. Disconnect the VGIS vacuum tank hose.
    18. Fig 7: Identifying Cover Screws
    GM1371851Courtesy of GENERAL MOTORS CORP.
  18. Remove the engine cover bolts and the cover.
  19. Disconnect the breather tube from the valve cover.
  20. Disconnect the crankcase ventilation tube from the valve cover.
    21. Fig 8: Identifying Fuel Injector Harness Connectors
    GM1371863Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the camshaft position (CMP) sensor connector.
  22. Disconnect the ignition wires from the spark plugs.
  23. Disconnect the fuel injector harness connectors.
    24. Fig 9: View Of Fuel Rail
    GM1371864Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the fuel line.
    25. Fig 10: View Of Alternator Adjusting Nut
    GM1371865Courtesy of GENERAL MOTORS CORP.
  25. Remove the bracket nut from the power steering pressure pipe.
  26. Remove the power steering pressure pipe.
  27. Remove the alternator adjusting nut.
    28. Fig 11: Locating EGR Valve
    GM1371866Courtesy of GENERAL MOTORS CORP.
  28. Remove the accessory drive bolt.
  29. Disconnect the exhaust gas recirculation (EGR) valve connector.
  30. Disconnect the ignition coil connector from the electronic ignition (EI) system.
  31. Disconnect the front heated oxygen sensor (HO2S) connector.
    32. Fig 12: Identifying Canister Purge Solenoid Valve
    GM1371867Courtesy of GENERAL MOTORS CORP.
  32. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation .
  33. Remove the engine under-cover bolt and the nuts.
  34. Remove the engine under-cover.
  35. Remove the canister purge solenoid valve at the intake manifold support bracket.
    36. Fig 13: View Of Intake Manifold Support Bracket
    GM1371868Courtesy of GENERAL MOTORS CORP.
  36. Remove the bracket bolts from the upper intake manifold support.
  37. Remove the bracket bolts from the lower intake manifold support.
  38. Disconnect the connector from the engine coolant temperature (ECT) sensor.
    39. Fig 14: View Of Exhaust Manifold Shield
    GM1371869Courtesy of GENERAL MOTORS CORP.
  39. Remove the exhaust manifold heat shield bolts.
  40. Remove the exhaust manifold heat shield.
  41. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
    42. Fig 15: View Of Thermostat Housing Upper Radiator Hose
    GM1371870Courtesy of GENERAL MOTORS CORP.
  42. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
  43. Disconnect the upper radiator hose from the thermostat housing.
    44. Fig 16: View Of Upper Front Timing Belt Cover And Bolts
    GM1371871Courtesy of GENERAL MOTORS CORP.
  44. Remove the cover bolts from the upper front timing belt.
  45. Remove the cover from the upper front timing belt.
    46. Fig 17: View Of Balancer
    GM1371872Courtesy of GENERAL MOTORS CORP.
  46. Remove the crankshaft pulley bolt.
  47. Remove the crankshaft pulley.
    48. Fig 18: View Of Lower Timing Belt Cover And Bolts
    GM1371873Courtesy of GENERAL MOTORS CORP.
  48. Remove the cover bolts from the lower front timing belt.
  49. Remove the cover from the lower front timing belt.
    50. Fig 19: Timing Marks On Camshaft Gears
    GM1750851Courtesy of GENERAL MOTORS CORP.
  50. Align the camshaft gear timing marks.
    51. Fig 20: Using J42492-A Rotating Coolant Pump
    GM1371883Courtesy of GENERAL MOTORS CORP.
  51. Slightly loosen the coolant pump retaining bolts.
  52. Rotate the coolant pump counterclockwise using J 42492-A  (1) to relieve the timing belt tension.
  53. Remove the timing belt. Refer to Timing Belt Replacement .
    54. Fig 21: View Of Intake And Exhaust Camshaft Gears
    GM1371885Courtesy of GENERAL MOTORS CORP.
  54. Remove the valve cover. Refer to Valve Rocker Arm Cover Replacement .
    55. NOTE: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.
  55. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  56. Remove the intake camshaft gear.
  57. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  58. Remove the exhaust camshaft gear.
    59. Fig 22: View Of Timing Belt Tensioner And Bolts
    GM1371891Courtesy of GENERAL MOTORS CORP.
  59. Remove the bolts from the timing belt automatic tensioner.
  60. Remove the timing belt automatic tensioner.
    61. Fig 23: View Of CMP Sensor
    GM1371892Courtesy of GENERAL MOTORS CORP.
  61. Remove the camshaft position (CMP) sensor bolts.
  62. Remove the CMP sensor.
    63. Fig 24: View Of Timing Belt Idler Pulley And Bolt
    GM1371894Courtesy of GENERAL MOTORS CORP.
  63. Remove the bolt from the timing belt idler pulley.
  64. Remove the timing belt idler pulley.
    65. Fig 25: View Of Rear Timing Belt Cover And Bolts
    GM1371895Courtesy of GENERAL MOTORS CORP.
  65. Remove the bolts from the rear timing belt cover.
  66. Remove the rear timing belt cover.
    67. Fig 26: View Of Heater Outlet Hose And Coolant Pipe
    GM1371896Courtesy of GENERAL MOTORS CORP.
  67. Disconnect the heater outlet hose from the coolant pipe.
    68. Fig 27: Removal Sequence Of Cylinder Head Bolts
    GM1371897Courtesy of GENERAL MOTORS CORP.
  68. Loosen all of the cylinder head bolts gradually and in the sequence shown.
  69. Remove the cylinder head bolts.
  70. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
    71. NOTE: Use extreme care when removing the cylinder head to prevent any engine oil, dirt, or coolant from entering the engine. Damage to the engine could result.
  71. Remove the cylinder head gasket.
  72. Disassembly the cylinder head, if applicable. Refer to Cylinder Head Disassemble .
  73. Clean and inspect the cylinder head as necessary. Refer to Cylinder Head Cleaning and Inspection .
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