Cylinder Head Cover Removal and Installation

Removal

1)Disconnect negative (–) cable at battery.

2)Remove air cleaner assembly.

3)Remove ignition coil assemblies.

4)Disconnect engine harness clamps and HO2S-1 harness clamp.

5)Remove air cleaner bracket (1).

6)Remove oil level gauge (2).

7)Disconnect PCV hose (3) from PCV valve (4).

8)Disconnect breather hose (5) from cylinder head cover.

9)Remove PCV valve from cylinder head cover, if necessary.

10)Remove engine harness bracket (6), if necessary.

11)Loosen cylinder head cover mounting bolts in numerical order (“1” – “7”) evenly and gradually.

12)Remove cylinder head cover (1) with gasket (2).

Installation

1)Remove oil, old sealant and dust from sealing surfaces on cylinder head and cover.

2)Install new gasket (2) to cylinder head cover (1).

3)Apply sealant “A” to the following point.

•Cylinder head cover gasket (1) sealing surface area (2) as shown.

“A”: Sealant 99000–31250 (SUZUKI Bond No.1207F)

•Timing chain cover (1) and cylinder head (2) mating surface as shown.

“A”: Sealant 99000–31250 (SUZUKI Bond No.1207F)

4)Install cylinder head cover to cylinder head.

NOTE:

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

5)Tighten cylinder head cover bolts according to the following procedure:

a)Tighten cylinder head cover bolts to 3.0 N·m (0.31 kgf-m, 2.5 lbf-ft) in numerical order (“1” – “7”) evenly and gradually.

b)Retighten them to 5.0 N·m (0.51 kgf-m, 4.0 lbf-ft) in the same manner as in Step a).

c)Retighten them to 7.5 N·m (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 N·m → 5.0 N·m → 7.5 N·m (0.31 kgf-m → 0.51 kgf-m→ 0.76 kgf-m, 2.5 lbf-ft → 4.0 lbf-ft → 5.5 lbf-ft)

6)Apply sealant to thread part of PCV valve (1), if removed.

“A”: Sealant 99000–31250 (SUZUKI Bond No.1207F)

a.	6 mm (0.24 in.)

7)Install PCV valve (1) to cylinder head cover and tighten PCV valve to specified torque, if removed.

Tightening torque

PCV valve (a): 27 N·m (2.8 kgf-m, 20.0 lbf-ft)

8)Connect PCV hose (2) to PCV valve.

9)Connect breather hose (3) to cylinder head cover.

10)Install oil level gauge (4).

11)Install air cleaner bracket (5).

12)Install engine harness bracket (6), if removed.

13)Install ignition coil assemblies.

14)Connect engine harness clamps and HO2S-1 harness clamp.

15)Install air cleaner assembly.

16)Connect negative (–) cable at battery.