Camshaft, Valve Lash Adjusters Removal & Installation: Installation

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Before installing valve lash adjuster to cylinder head (1), fill oil passage of cylinder head with engine oil according to the following procedure.
Pour engine oil through oil holes (2) and check that oil comes out from oil holes (2) and check that oil comes out from oil holes (2) in sliding part of valve lash adjuster.

Perform this check on both intake and exhaust sides.

Fig 1: Checking Valve Lash Adjuster Oil Passages
Courtesy of SUZUKI OF AMERICA CORP.
Install valve lash adjusters to cylinder head.
Apply engine oil around valve lash adjuster and then install it to cylinder head.

Fig 2: Installing Valve Lash Adjusters
Courtesy of SUZUKI OF AMERICA CORP.
Match key (1) on crankshaft to timing mark (2) as shown in the figure.

Fig 3: Aligning Crankshaft Timing Mark
Courtesy of SUZUKI OF AMERICA CORP.
Install camshafts.
Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks on cylinder head and pins on camshafts as shown in the figure.

NOTE: Install camshaft in such direction that its end with groove for CMP sensor installation comes to exhaust side.

Fig 4: Aligning Match Marks On Cylinder Head & Pins On Camshafts
Courtesy of SUZUKI OF AMERICA CORP.
Install camshaft housing pins as shown in the figure.
Apply sealant "A" to exhaust camshaft end housing sealing surface area as shown in the figure.
1. "A": Sealant 99000-31250
Fig 5: Identifying Camshaft Housing Pins & Identifying Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.
Check position of camshaft housings.
Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.

Fig 6: Identifying Position Of Camshaft Housings
Courtesy of SUZUKI OF AMERICA CORP.
After applying oil to housing bolts, lighten them temporarily first. Them by the following sequence ("1" - "23") as indicated in the figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence 2 or 3 times before they are tighten to specified torque.
Tightening torque
1. Camshaft housing bolt (a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
Fig 7: Identifying Camshaft Housing Bolts Tightening Sequence
Courtesy of SUZUKI OF AMERICA CORP.
Install CMP sensor. See INSTALLATION .
Install 2nd timing chain. See 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
Install timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
Install oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
Adjust cooling fan belt tension. See COOLING FAN BELT TENSION CHECK & ADJUSTMENT .
Refill cooling system with coolant, front differential with gear oil, engine with engine oil and power steering system with specified fluid.
Verify that there is no coolant leakage, oil leakage, power steering fluid leakage and exhaust gas leakage at each connection.
Check ignition timing and adjust as necessary. See VITARA (2.0L), GRAND VITARA (2.5L) & XL-7 (2.7) .
CAUTION:
- Don't turn camshafts or start engine (i.e., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshafts. As it takes time for valves to settle in place, operating engine within half an hour after their installation may cause interference to occur between valves themselves or valves and piston.
- If air is trapped in valve lash adjuster, valve may make tapping sound when engine is operated after valve lash adjuster is installed. In such a case, run engine for about half an hour at about 2,000 rpm, and then air will be purged and tapping sound will cease. Should tapping sound not cease, it is possible that valve lash adjuster is defective. Replace it if defective.
  If defective can't be located by hearing amount 16 of them, check as follows.
  1. Stop engine and remove cylinder head cover.
  2. Push adjuster downward by hand (with less than 20 kg or 44 lbs force) when cam crest is not on adjuster to be checked and check if clearance exists between cam and adjuster. If it does, adjuster. If it does, adjuster is defective and needs replacement.