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Camshafts and Valve Lash Adjusters Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
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 2000 to 3000 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 adjuster can't be located by hearing among 24 of them, check as follows.

    • Stop engine and remove cylinder head cover.
    • Push adjuster downward by hand (with less than 20 kg or 44 lbs force) when can crest is not on adjuster to be checked and check if clearance exists between cam and adjuster. If it does, adjuster is defective and needs replacement.
  1. Before installing valve lash adjuster to cylinder head, fill oil passage of cylinder head (1) 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) in sliding part of valve lash adjuster.

    Perform this check on both intake and exhaust sides.

    Fig 1: Filling Oil Passage Of Cylinder Head With Engine Oil
    G02256775Courtesy of SUZUKI OF AMERICA CORP.
  2. Apply engine oil around valve lash adjuster and then install it to cylinder head.
    Fig 2: Applying Engine Oil Around Valve Lash Adjuster
    G02256776Courtesy of SUZUKI OF AMERICA CORP.
  3. Check timing mark on crankshaft as shown in the figure.
    Fig 3: Checking Timing Mark On Crankshaft
    G02256777Courtesy of SUZUKI OF AMERICA CORP.
  4. Install RH bank camshafts referring to "RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  5. Install LH bank camshafts.

    Apply oil to sliding surface of each camshaft and camshaft journal then install them by aligning match marks (4) on cylinder head (3) and LH bank camshafts as shown in the figure.

    Fig 4: Applying Oil To Sliding Surface & Installing Aligning Match Marks
    G02256778Courtesy of SUZUKI OF AMERICA CORP.
  6. Install LH bank camshaft housing pins as shown in Fig 5.
  7. Apply sealant "A" to LH bank exhaust camshaft housing No. 5 sealing surface area as shown in the figure.

    "A": Water tight sealant 99000-31250 

    Fig 5: Installing LH Bank Camshaft Housing Pins
    G02256779Courtesy of SUZUKI OF AMERICA CORP.
  8. Check position of LH bank 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: Checking Position Of LH Bank Camshaft Housings
    G02256780Courtesy of SUZUKI OF AMERICA CORP.
  9. After applying oil to housing bolts, tighten them temporarily first.

    Then tighten them by the following sequence ("1" - "19") 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 tightened to specified torque below.

    Tightening torque 

    Camshaft housing bolt: Tighten 11 N.m (1.1 kg-m, 8.0 lb-ft) by the specified procedure 

    Fig 7: Tightening Bolts In Sequence
    G02256781Courtesy of SUZUKI OF AMERICA CORP.
  10. Install 1st timing chain. Refer to "1ST TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  11. Install LH bank 2nd timing chain. Refer to "LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  12. Install timing chain cover. Refer to "TIMING CHAIN COVER REMOVAL AND INSTALLATION: ".
  13. Install oil pan referring to "OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION ".
  14. Install front differential housing referring to "FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING ".
  15. Install P/S system referring to "POWER STEERING PUMP REMOVAL AND INSTALLATION ".
  16. Install cooling system referring to "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTAL ".
  17. Install intake manifold with throttle body referring to "THROTTLE BODY AND INTAKE MANIFOLD INSTALLATION ".
  18. Install CMP sensor. Refer to "CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION ".
  19. Refill cooling system referring to "COOLING SYSTEM FLUSH AND REFILL ".
  20. Refill front differential housing with gear oil referring to "FRONT DIFFERENTIAL GEAR OIL INSPECTION AND CHANGE ", if necessary.
  21. Refill P/S system with specified fluid referring to "POWER STEERING SYSTEM AIR BLEEDING PROCEDURE "
  22. Check wheel alignment referring to "WHEEL ALIGNMENT SPECIFICATIONS ".
  23. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
  24. Check ignition timing, referring to "IGNITION TIMING CHECK AND ADJUSTMENT ".
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