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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (2.0L 4-Cylinder) >> Repair Instructions >> Valves & Cylinder Head Removal

Valves & Cylinder Head Removal

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.
  1. Relieve fuel pressure according to procedure described in RELIEVING FUEL PRESSURE .
  2. Disconnect negative cable at battery.
  3. Drain engine oil.
  4. Drain coolant.
  5. Remove strut tower bar (1).
    Fig 1: Identifying Strut Tower Bar
    G01351907Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove air cleaner outlet hose.
  7. Disconnect the following electric lead wires:
    • EGR valve coupler.
    • IAC valve coupler
    • TP sensor coupler
    • EVAP canister purge valve coupler
    • Ground terminal from intake manifold
    • Heated oxygen sensor-1 and/or -2 coupler
    • CMP sensor coupler
    • ECT sensor coupler
    • Injector wire harness coupler
    • Ground wire at the coupler
    • Ignition coils coupler
    • Wire harness clamps
    Fig 2: Identifying Wire Harness Couplers
    G01351908Courtesy of SUZUKI OF AMERICA CORP.
  8. Disconnect accelerator cable and A/T throttle cable (for vehicle with A/T) from throttle body.
  9. Disconnect the following hoses:
    • Brake booster hose from intake manifold
    • Vacuum hose from intake manifold
    • Canister purge hose from EVAP canister
    • Water hose from bypass pipe
    • Fuel feed hose and return hose from each pipe
    • Heater hose from heater outlet pipe
    • Radiator inlet hose from water outlet pipe
    Fig 3: Identifying Engine Hoses
    G01351909Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove intake manifold rear stiffener.
  11. Detach water pipe from intake manifold.
  12. Remove cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
  13. Remove oil pan and oil pump strainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
  14. Remove timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
  15. Remove 2nd timing chain. See 2ND TIMING CHAIN & CHAIN TENSIONER REMOVAL .
  16. Remove 1st timing chain. See 1ST TIMING CHAIN & CHAIN TENSIONER REMOVAL .
  17. Remove camshafts and valve lash adjusters. See CAMSHAFT, VALVE LASH ADJUSTERS REMOVAL & INSTALLATION .
  18. Disconnect exhaust No. 1 pipe (1) from exhaust manifold.
    Fig 4: Identifying Exhaust System Components
    G01351910Courtesy of SUZUKI OF AMERICA CORP.
  19. Remove exhaust manifold stiffener (1) (if equipped).
    Fig 5: Identifying Exhaust Manifold Stiffener
    G01351911Courtesy of SUZUKI OF AMERICA CORP.
  20. Loosen cylinder head bolts in such order (1 - 10) as indicated in the figure and remove them.
    NOTE: Don't forget to remove bolt (M6) shown in the figure.
    Fig 6: Identifying Cylinder Head Bolts Loosening Sequence
    G01351912Courtesy of SUZUKI OF AMERICA CORP.
  21. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
  22. Remove cylinder head with intake manifold, exhaust manifold and water outlet pipe. Use lifting device if necessary.
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