Cylinder Head Cover Removal and Installation

Cylinder Head Cover Removal and Installation

Cylinder Head Cover Components

Removal

1) Disconnect negative (-) cable at battery.
2) Remove engine cover.
3) Remove ignition coil assemblies from cylinder head cover. Ignition Coil Assembly Removal and Installation
4) Disconnect IMT valve connector (1) and IMT valve harness clamp (2).





5) Disconnect PCV valve hose (1) and breather hose (2).
6) Detach engine harness clamps.
7) Remove engine harness bracket (3).





8) Remove cylinder head cover bolts.
9) Remove cylinder head cover with its gasket.
10) Remove PCV valve if necessary.

Installation

1) Tighten PCV valve to specified torque, if removed.

Tightening torque
PCV valve 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)

2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover.
3) Install new cylinder head cover gasket (1) to cylinder head cover (2) as shown in figure.





4) Apply sealant "A" to the designated area as shown in figure.

"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)





5) Install cylinder head cover to cylinder head.

NOTE:
Install cylinder head cover, making sure cylinder head cover gasket for proper fit in cylinder head cover.

6) Tighten cylinder head cover bolts using the following procedures:
a) Tighten cylinder head cover bolts to 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft) in numerical order ("1" - "16") evenly and gradually.
b) Retighten them to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft). In the same manner as in Step a).
c) Retighten them to 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft). In the same manner as in Step a).

Tightening torque
Cylinder head cover bolt* (a): (3.0 Nm -> 5.0 Nm -> 7.5 Nm (0.31 kgf-m -> 0.51 kgf-m -> 0.76 kgf-m, 2.5 lbf-ft -> 4.0 lbf-ft -> 5.5 lbf-ft))

7) Install engine harness bracket (1).
8) Connect PCV valve hose (2) to PCV valve and breather hose (3) to cylinder head cover.





9) Connect IMT valve connector (1) and IMT valve harness clamp (2).





10) Install ignition coil assemblies. Ignition Coil Assembly Removal and Installation
11) Install engine cover.
12) Connect negative (-) cable at battery.