LEMON Manuals: Even more car manuals for everyone
Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 129 (2.5L V6) >> Repair Instructions >> Valves & Cylinder Heads Removal & Installation >> Installation

Valves & Cylinder Heads Removal & Installation: Installation

WARNING: This page is about a different car, the 2004 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. Apply sealant "A" to cylinder head gasket (1) as shown in the figure.

    "A":  Water tight sealant 99000-31250

    Sealant amount 

    Width "w":  4 mm (0.158 in.)

  4. Install new cylinder head gasket (1) to cylinder block as shown in the figure. Carved lot number (5) on cylinder head gasket (1) should face up (toward cylinder head side).
    Fig 1: Installing Cylinder Head Gasket
    G02264003Courtesy of SUZUKI OF AMERICA CORP.
  5. 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 kg-m, 38.5 lb-ft) according to numerical order in the figure.
    2. In the same manner as Step  A, tighten them to 84 N.m (8.4 kg-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 kg-m, 38.5 lb-ft).
    5. In the same manner as Step  A again, tighten them to specified torque.
    6. Tighten cylinder head bolts (hex hole bolt) to specified torque.

      Tightening torque 

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

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

    NOTE: Be sure to install hex hole bolts (1) as shown in the figure.
    Fig 2: Installing Hex Hole Bolts
    G02264004Courtesy of SUZUKI OF AMERICA CORP.
  6. Install water outlet cap.
  7. Check timing mark on crankshaft as shown in the figure.
    Fig 3: Checking Timing Mark On Crankshaft
    G02264005Courtesy of SUZUKI OF AMERICA CORP.
  8. Install valve lash adjuster, camshaft, CMP sensor and RH bank 2nd timing chain.

    Refer to CAMSHAFTS & VALVE LASH ADJUSTERS REMOVAL & INSTALLATION  and RH (NO. 2) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION  . For CMP sensor, refer to CAMSHAFT POSITION (CMP) SENSOR REMOVAL & INSTALLATION .

  9. Install 1st timing chain referring to 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION  .
  10. Install LH bank 2nd timing chain referring to LH (NO. 1) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION  .
  11. Install timing chain cover referring to TIMING CHAIN COVER REMOVAL & INSTALLATION  .
  12. Install oil pan and oil pump strainer referring toOIL PAN & OIL PUMP STRAINER REMOVAL & INSTALLATION .
  13. Install cylinder head cover referring to CYLINDER HEAD COVERS REMOVAL & INSTALLATION  .
  14. Install exhaust manifold referring to EXHAUST MANIFOLD REMOVAL & INSTALLATION .
  15. Install radiator outlet pipe, radiator, cooling fan and water hose.

    Refer to COOLING WATER PIPES OR HOSES REMOVAL & INSTALLATION , RADIATOR REMOVAL & INSTALLATION and COOLING FAN & FAN CLUTCH REMOVAL & INSTALLATION .

  16. Install intake manifold with throttle body.

    Refer to THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION (H25 ENGINE)  .

  17. Adjust water pump drive belt tension.

    Refer to COOLING FAN/GENERATOR BELT TENSION CHECK & ADJUSTMENT .

  18. Adjust power steering pump drive belt tension referring to P/S PUMP DRIVE BELT INSPECTION & ADJUSTMENT .
  19. Adjust accelerator cable play and A/T throttle cable play. Refer to ACCELERATOR CABLE ADJUSTMENT  and A/T THROTTLE CABLE ADJUSTMENT (H25 ENGINE WITH A/T ONLY)  .
  20. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  21. Refill engine with engine oil .
  22. Refill cooling system referring to COOLING SYSTEM FLUSH & REFILL .
  23. Refill front differential housing with gear oil if drained.

    Refer to MANUAL TRANSMISSION GEAR OIL INSPECTION & CHANGE .

  24. Connect negative (-) cable at battery.
  25. Check ignition timing and adjust as necessary referring to IGNITION TIMING CHECK & ADJUSTMENT .
  26. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.
  27. Check wheel alignment referring to SPECIFICATIONS & PROCEDURES .
scientia non olet · About LEMON Manuals