Valves & Cylinder Head 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.

Clean mating surface of cylinder head and cylinder block (2). Remove oil, old gasket and dust from mating surface.
Install knock pins (3) to cylinder block (2).
Install new cylinder head gasket (1) to cylinder block (2). "TOP" mark provided on gasket comes to crankshaft pulley side (4), facing up (toward cylinder head side).

Fig 1: Identifying Cylinder Head Gasket Installation Position
Courtesy of SUZUKI OF AMERICA CORP.
Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows.
1. Tighten all bolts to 53 N-m (5.3 kg-m, 38.5 lb-ft) according to numerical order (1-10) in the figure.
2. In the same manner as in Step a), tighten them to 84 N-m (8.4 kg-m, 61.0 lb-ft).
  
  Fig 2: Identifying Cylinder Head Tightening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
3. Loosen all bolts until tightening torque is reduced to 0 in the illustrated order (1-10).
  
  Fig 3: Identifying Cylinder Head Loosening Sequence
  Courtesy of SUZUKI OF AMERICA CORP.
4. Tighten all bolts to 53 N-m (5.3 kg-m, 38.5 lb-ft) according to numerical order (1-10) in the figure.
5. In the same manner as in Step d) again, tighten them to specified torque.
  Tightening torque
  1. Cylinder head bolt (a): 105 N-m (10.5 kg-m, 76.0 lb-ft)
  2. Cylinder head bolt (hex hole bolt) (b): 11 N-m (1.1 kg-m, 8.0 lb-ft)
  NOTE: Be sure to tighten M6 a bolt after securing the other bolt.
Fig 4: Identifying Cylinder Head Tightening Sequence & M6 Bolt Location
Courtesy of SUZUKI OF AMERICA CORP.
Check that crank timing sprocket key (2) on crankshaft aligns with timing mark (1) as shown in the figure.

Fig 5: Identifying Crank Timing Sprocket Key & Crankshaft Alignment Mark
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust manifold stiffener (if equipped) and connect exhaust No. 1 pipe to exhaust manifold. See EXHAUST MANIFOLD REMOVAL & INSTALLATION .
Install camshafts and valve lash adjusters. See CAMSHAFT, VALVE LASH ADJUSTERS REMOVAL & INSTALLATION .
Install 1st timing chain. See 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
Install 2nd timing chain. See 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
Install timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
Install oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
Install intake manifold rear stiffener and connect water pipe to intake manifold.
Install each hoses and electric lead wires.
Install air cleaner outlet hoses.
Install strut tower bar.
Adjust cooling fan belt tension. See COOLING FAN BELT TENSION CHECK & ADJUSTMENT .
Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T). SeeACCELERATOR CABLE ADJUSTMENT and A/T THROTTLE CABLE ADJUSTMENT (FOR A/T VEHICLE) .
Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
Refill engine with engine oil.
Refill cooling system. See COOLING SYSTEM FLUSH & REFILL .
Refill front differential housing with gear oil. See FRONT DIFFERENTIAL GEAR OIL INSPECTION & CHANGE .
Refill power steering system with specified fluid.
Connect negative cable at battery.
Verify that there is no fuel leakage, coolant leakage, oil 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) .