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Valves and Cylinder Heads 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.
  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 Fig 1.

    "A": Water tight sealant 99000-31250 

    Sealant amount (width "w")

    Min. 4 mm (0.157 in.) 

  4. Install new cylinder head gasket (1) to cylinder block as shown in the figure. "86FA" mark (5) on cylinder head gasket (1) should face up (toward cylinder head side).
    Fig 1: Installing Cylinder Head Gasket To Cylinder Block
    G02256792Courtesy 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 105 N.m (10.5 kg-m, 76.0 lb-ft).
    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, 8.0 lb-ft) 

    NOTE: Don't forget to install hex hole bolts (1) as shown in the figure.
    Fig 2: Installing hex Hole Bolts
    G02256793Courtesy 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
    G02256794Courtesy of SUZUKI OF AMERICA CORP.
  8. Install valve lash adjuster and camshaft referring to "CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION ".
  9. Install CMP sensor referring to "CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION ".
  10. Install RH bank 2nd timing chain referring to "RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  11. Install 1st timing chain. Refer to "1ST TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  12. Install LH bank 2nd timing chain. Refer to "LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
  13. Install timing chain cover. Refer to "TIMING CHAIN COVER REMOVAL AND INSTALLATION: ".
  14. Install oil pan and oil pump strainer. Refer to "OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION ".
  15. Install cylinder head cover. Refer to "CYLINDER HEAD COVERS REMOVAL AND INSTALLATION ".
  16. Install exhaust manifold. Refer to "EXHAUST MANIFOLD REMOVAL AND INSTALLATION ".
  17. Install radiator outlet pipe radiator, cooling fan and water hose. Refer to "COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION ", "RADIATOR REMOVAL AND INSTALLATION " and "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION ".
  18. Install throttle body and intake manifold. Refer to "THROTTLE BODY AND INTAKE MANIFOLD INSTALLATION ".
  19. Adjust water pump drive belt tension. Refer to "COOLING FAN / GENERATOR BELT CHECK AND ADJUSTMENT ".
  20. Adjust power steering pump drive belt tension. Refer to "COOLING FAN / GENERATOR BELT CHECK AND ADJUSTMENT ".
  21. Adjust accelerator cable play and A/T throttle cable play. Refer to "Accelerator Cable Adjustment  and A/T Throttle Cable Adjustment (for A/T Vehicle)  ".
  22. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  23. Refill engine with engine oil referring to appropriate maintenance for engine oil and filter change.
  24. Refill cooling system referring to "COOLING SYSTEM FLUSH AND REFILL ".
  25. Refill front differential housing with gear oil referring to "FRONT DIFFERENTIAL GEAR OIL INSPECTION AND CHANGE ", if necessary.
  26. Connect negative cable at battery.
  27. Check ignition timing and adjust as necessary referring to "IGNITION TIMING CHECK AND ADJUSTMENT ".
  28. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.
  29. Check wheel alignment referring to "WHEEL ALIGNMENT SPECIFICATIONS ".
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