Cylinder Head Cover Removal and Installation

Cylinder Head Cover Removal and Installation

Cylinder Head Cover Components

Removal

1) Disconnect negative (-) cable from battery.
2) Remove engine cover. Air Cleaner Assembly Removal and Installation
3) Remove ignition coil assemblies from cylinder head cover. Ignition Coil Assembly Removal and Installation
4) Disconnect PCV valve hose (1) and breather hose (2).
5) Detach engine harness clamps.
6) Loosen cylinder head cover bolts in numerical order ("1" - "16") evenly and gradually.





7) Remove cylinder head cover with its gasket.
8) Remove PCV valve if necessary.

Installation

1) Install new cylinder head cover gasket (1) to cylinder head cover (2) as shown in figure.





2) Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant "A" to the designated area in figure.

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





3) Install cylinder head cover to cylinder head.

NOTE:
When installing cylinder head cover, use care so that cylinder head cover gasket does not get out of place or fall off.

4) Tighten cylinder head cover bolts according to the following procedure.
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) In the same manner as Step a), retighten them to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) In the same manner as Step a), retighten them to 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft).

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))

5) Connect PCV valve hose (1) to PCV valve and breather hose (2) to cylinder head cover.





6) Install ignition coil assemblies. Ignition Coil Assembly Removal and Installation
7) Install engine cover. Air Cleaner Assembly Removal and Installation
8) Connect negative (-) cable to battery.