Suzuki Esteem, Swift 1994-02

Cylinder Head

Print

Removal & Installation



1.3L Engine

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner assembly
     
    Ignition coil wire from the distributor cap, if equipped
     
    Distributor electrical wires, if equipped
     
    Ignition coil assembly, if equipped
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Radiator fan thermo switch
     
    Engine Coolant Temperature (ECT) sensor
     
    ECT gauge sensor
     
    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Fuel injector
     
    Ground wires from the intake manifold.
     
    Oxygen (O 2 S) sensor
     
    Radiator hose from the thermostat housing
     
    Heater hose from the intake manifold
     
    Throttle body coolant outlet hose from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold, if equipped
     
    Canister hose from its pipe
     
    Canister purge hose from the intake manifold
     
    Brake booster from the intake manifold
     
    Fuel return hose and the fuel feed hose from the throttle body
     
    Throttle cable from the throttle body
     
    Water pump and crankshaft pulleys
     
    Timing belt
     
    Rubber seal between the cylinder head and the water pump
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wire clamps from the cylinder head cover
     
    Positive Crankcase Ventilation (PCV) hose
     
    Cylinder head cover
     

  8.  
  9. Loosen all valve adjusting screws and allow the valves to close.
  10.  
  11. Remove or disconnect the following:

    Cylinder head bolts in the reverse order of the tightening sequence
     
    Cylinder head with the distributor, intake manifold and exhaust manifold
     
    Distributor, intake manifold and exhaust manifold from the cylinder head
     

  12.  
  13. Clean the cylinder block mating surface of any old gasket material and clean any engine coolant from the cylinders.
  14.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-1.3L engine

  1. Install or connect the following:

    Intake and exhaust manifolds
     
    Distributor on the cylinder head
     
    New cylinder head gasket with the top mark facing up and toward the crankshaft pulley
     
    Cylinder head on the engine block
     

  2.  
  3. Coat the cylinder head mounting bolts threads with clean engine oil.
  4.  
  5. Tighten the bolts as follows:
    1. Step 1: 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm).
    4.  
    5. Step 3: 49 ft. lbs. (68 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Rubber seal between the cylinder head and the water pump
     
    Timing belt
     
    Exhaust pipe to the exhaust manifold, tighten the attaching bolts to 26-36 ft. lbs. (35-50 Nm)
     
    Crankshaft and water pump pulleys
     
    Throttle cable to the throttle body
     
    Fuel return hose and the fuel feed hose to the throttle body
     
    Remaining components in the reverse order of removal
     

  8.  
  9. Refill the cooling system with coolant.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Adjust the ignition timing.
  14.  
  15. With the engine running, be sure that there are no fuel, coolant or exhaust leaks.
  16.  


CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner assembly
     
    Ignition coil wire from the distributor cap, if equipped
     
    Distributor electrical wires, if equipped
     
    Ignition coil assembly, if equipped
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Radiator fan thermo switch
     
    Engine Coolant Temperature (ECT) sensor
     
    ECT gauge sensor
     
    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Fuel injector
     
    Ground wires from the intake manifold.
     
    Oxygen (O 2 S) sensor
     
    Radiator hose from the thermostat housing
     
    Heater hose from the intake manifold
     
    Throttle body coolant outlet hose from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold, if equipped
     
    Canister hose from its pipe
     
    Canister purge hose from the intake manifold
     
    Brake booster from the intake manifold
     
    Fuel return hose and the fuel feed hose from the throttle body
     
    Throttle cable from the throttle body
     
    Water pump and crankshaft pulleys
     
    Timing belt
     
    Rubber seal between the cylinder head and the water pump
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wire clamps from the cylinder head cover
     
    Positive Crankcase Ventilation (PCV) hose
     
    Cylinder head cover
     

  8.  
  9. Loosen all valve adjusting screws and allow the valves to close.
  10.  
  11. Remove or disconnect the following:

    Cylinder head bolts in the reverse order of the tightening sequence
     
    Cylinder head with the distributor, intake manifold and exhaust manifold
     
    Distributor, intake manifold and exhaust manifold from the cylinder head
     

  12.  
  13. Clean the cylinder block mating surface of any old gasket material and clean any engine coolant from the cylinders.
  14.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-1.3L engine

  1. Install or connect the following:

    Intake and exhaust manifolds
     
    Distributor on the cylinder head
     
    New cylinder head gasket with the top mark facing up and toward the crankshaft pulley
     
    Cylinder head on the engine block
     

  2.  
  3. Coat the cylinder head mounting bolts threads with clean engine oil.
  4.  
  5. Tighten the bolts as follows:
    1. Step 1: 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm).
    4.  
    5. Step 3: 49 ft. lbs. (68 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Rubber seal between the cylinder head and the water pump
     
    Timing belt
     
    Exhaust pipe to the exhaust manifold, tighten the attaching bolts to 26-36 ft. lbs. (35-50 Nm)
     
    Crankshaft and water pump pulleys
     
    Throttle cable to the throttle body
     
    Fuel return hose and the fuel feed hose to the throttle body
     
    Remaining components in the reverse order of removal
     

  8.  
  9. Refill the cooling system with coolant.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Adjust the ignition timing.
  14.  
  15. With the engine running, be sure that there are no fuel, coolant or exhaust leaks.
  16.  

1.6L Engine

CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Air cleaner outlet hose
     
    Intake manifold rear stiffener bolt, alternator adjustment arm reinforcement bolt and right mounting bracket stiffener from the intake manifold
     
    Heated Oxygen (HO 2 S) sensor coupler and release its clamps
     
    Exhaust from the manifold
     

  8.  
  9. Disconnect the electrical connectors from the following components:

    Distributor, if equipped
     
    Ignition coils, if equipped
     
    Engine Coolant Temperature (ECT) sensor and gauge
     
    Engine ground wire from intake manifold
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Heated Oxygen (HO 2 S) sensor
     
    Evaporative Emissions (EVAP) canister purge valve, if equipped
     
    Manifold Absolute Pressure (MAP) sensor, if equipped
     
    Tank pressure control solenoid vacuum valve, if equipped
     
    Camshaft Position (CMP) sensor, if equipped
     
    Evaporative emissions solenoid purge valve
     

  10.  
  11. Label and disconnect the vacuum hoses from the following:

    Evaporative Emissions (EVAP) canister purge hose
     
    Brake booster supply hose
     

  12.  
  13. Remove or disconnect the following:

    Fuel feed and return hoses from each pipe
     
    Cylinder head cover
     
    Valve lash adjusting screws
     

  14.  
  15. Disconnect the following hoses:

    Radiator inlet hose
     
    Heater inlet hose
     
    IAC valve outlet
     

  16.  
  17. Remove or disconnect the following:

    Timing belt
     
    Cylinder head bolts in reverse order of tightening. Once each bolt is loose, remove the bolts from the cylinder head.
     

  18.  
  19. Check to be sure all components are removed or disconnected before removing the cylinder head.
  20.  
  21. Remove the cylinder head with the intake manifold, exhaust manifold and distributor as an assembly.
  22.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-1.6L engine

  1. Install a new cylinder head gasket and the cylinder head, with the distributor case, onto the cylinder block.
  2.  
  3. Tighten the cylinder head bolts, in sequence, using the following 3 Steps:
    1. Step 1: 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm).
    4.  
    5. Step 3: 49 ft. lbs. (68 Nm).
    6.  

  4.  
  5. Install or connect the following:

    Timing belt
     
    Engine cooling water hoses
     

  6.  
  7. Adjust the valve lash.
  8.  
  9. Install or connect the following:

    Cylinder head cover
     
    Fuel feed and return hoses to each pipe
     
    Vacuum hoses
     
    All remaining electrical components
     
    All remaining components in the reverse order of removal
     

  10.  
  11. Fill the engine coolant and check all fluids.
  12.  
  13. Connect the negative battery cable to the battery.
  14.  
  15. Start the engine and check for leaks.
  16.  


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Air cleaner outlet hose
     
    Intake manifold rear stiffener bolt, alternator adjustment arm reinforcement bolt and right mounting bracket stiffener from the intake manifold
     
    Heated Oxygen (HO 2 S) sensor connector and release its clamps
     
    Exhaust from the manifold
     

  8.  
  9. Disconnect the electrical connectors from the following components:

    Distributor, if equipped
     
    Ignition coils, if equipped
     
    Engine Coolant Temperature (ECT) sensor and gauge
     
    Engine ground wire from intake manifold
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Heated Oxygen (HO 2 S) sensor
     
    Evaporative Emissions (EVAP) canister purge valve, if equipped
     
    Manifold Absolute Pressure (MAP) sensor, if equipped
     
    Tank pressure control solenoid vacuum valve, if equipped
     
    Camshaft Position (CMP) sensor, if equipped
     
    Evaporative emissions solenoid purge valve
     

  10.  
  11. Label and disconnect the vacuum hoses from the following:

    Evaporative Emissions (EVAP) canister purge hose
     
    Brake booster supply hose
     

  12.  
  13. Remove or disconnect the following:

    Fuel feed and return hoses from each pipe
     
    Cylinder head cover
     
    Valve lash adjusting screws
     

  14.  
  15. Disconnect the following hoses:

    Radiator inlet hose
     
    Heater inlet hose
     
    IAC valve outlet
     

  16.  
  17. Remove or disconnect the following:

    Timing belt
     
    Cylinder head bolts in reverse order of tightening. Once each bolt is loose, remove the bolts from the cylinder head.
     

  18.  
  19. Check to be sure all components are removed or disconnected before removing the cylinder head.
  20.  
  21. Remove the cylinder head with the intake manifold, exhaust manifold and distributor as an assembly.
  22.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-1.6L engine

  1. Install a new cylinder head gasket and the cylinder head, with the distributor case, onto the cylinder block.
  2.  
  3. Tighten the cylinder head bolts, in sequence, using the following 3 Steps:
    1. Step 1: 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm).
    4.  
    5. Step 3: 49 ft. lbs. (68 Nm).
    6.  

  4.  
  5. Install or connect the following:

    Timing belt
     
    Engine cooling water hoses
     

  6.  
  7. Adjust the valve lash.
  8.  
  9. Install or connect the following:

    Cylinder head cover
     
    Fuel feed and return hoses to each pipe
     
    Vacuum hoses
     
    All remaining electrical components
     
    All remaining components in the reverse order of removal
     

  10.  
  11. Fill the engine coolant and check all fluids.
  12.  
  13. Connect the negative battery cable to the battery.
  14.  
  15. Start the engine and check for leaks.
  16.  

1.8L Engine

CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain engine oil.
  10.  
  11. Remove ignition coil cover.
  12.  
  13. Remove air cleaner case with air cleaner outlet hose.
  14.  
  15. Disconnect accelerator cable from throttle body.
  16.  
  17. Remove accelerator cable from bracket.
  18.  
  19. Disconnect the following hoses:

    Brake booster hose from intake manifold
     
    Coolant hose from throttle body
     
    Fuel feed hose from delivery pipe
     
    Fuel return hose from fuel return pipe
     
    Heater hose from water outlet cap
     
    Radiator inlet hose from water outlet cap
     
    Vacuum hose from EVAP canister purge valve
     

  20.  
  21. Disconnect the following electric lead wires:

    IAC valve connector
     
    TP sensor connector
     
    MAF sensor connector
     
    EGR valve connector
     
    EVAP canister purge valve connector
     
    MDP sensor connector
     
    Ground terminals from cylinder head and throttle body
     
    ECT sensor connector
     
    CMP sensor connector
     
    Injector wire harness connector
     
    Ignition coil connectors
     
    Wire harness clamps
     

  22.  
  23. Remove intake manifold rear stiffener.
  24.  
  25. Disconnect coolant pipe from intake manifold.
  26.  
  27. Remove timing chain cover.
  28.  
  29. Remove 1st timing chain.
  30.  
  31. Remove camshafts and valve lash adjuster.
  32.  
  33. Remove engine RH mounting bracket.
  34.  
  35. Disconnect power steering pump and alternator from power steering pump bracket. If mounting bolts of P/S pump cannot be removed, remove front torque bush and rear mounting from mounting member and raise engine by using lifting device and remove bolts.
    CAUTION
    Do not raise engine excessively. That may cause damage to engine, transmission, etc.

  36.  
  37. Remove P/S pump bracket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence: crankshaft pulley side (1), flywheel side (2), M6 bolt (3)-1.8L engine

  38.  
  39. Install engine rear mounting No.2 bracket front torque bush and rear mounting to mounting member to stabilize engine if removed. Loosen cylinder head bolts in such order as numbered in the figure and remove them. Don-t forget to remove bolt (M6) as shown in the figure.
  40.  
  41. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
  42.  
  43. Remove cylinder head with intake manifold, exhaust manifold and water outlet cap. Be careful not to damage fins of radiator.
  44.  

To install:

  1. Match match mark on crank timing sprocket and mating surface of cylinder block and lower crankcase.
  2.  
  3. Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
  4.  
  5. Install knock pins to cylinder block.
  6.  
  7. Install new cylinder head gasket to cylinder block. Top mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side).

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence: crankshaft pulley side (1), flywheel side (2), M6 bolt (3)-1.8L engine

  8.  
  9. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows:


    1. Tighten all bolts to 39 ft. lbs. (53 Nm) according to numerical order in the figure.
    2.  
    3. In the same manner as in the first step, retighten them to 61 ft. lbs. (84 Nm).
    4.  
    5. Loosen all bolts according to the bolt loosening sequence until tightening torque is reduced to 0 according to numerical order in the figure.
    6.  
    7. Tighten all bolts to 27 ft. lbs. (37 Nm) according to numerical order in the figure.
    8.  
    9. In the same manner as in the previous step, retighten them to 76 ft. lbs. (105 Nm).
    10.  
    11. After securing the other bolts, be sure to tighten the M6 bolt to 8 ft. lbs. (11 Nm).
    12.  

  10.  
  11. Install engine RH mounting bracket and tighten bracket bolts to 40 ft. lbs. (55 Nm).
  12.  
  13. Install power steering pump bracket.
  14.  
  15. Install power steering pump and alternator-to-power steering pump bracket.
  16.  
  17. Install camshafts and valve lash adjuster.
  18.  
  19. Install 1st timing chain.
  20.  
  21. Install 2nd timing chain.
  22.  
  23. Install timing chain cover.
  24.  
  25. Reverse removal procedure for installation.
  26.  
  27. Adjust accelerator cable play as follows:


    1. Warm up engine to normal operating temperature. And check to make sure that fast idle control cam is off cam follower lever.
    2.  
    3. With throttle valve closed, check accelerator pedal play which should measure 0.08-0.27 inch (2-7mm). If measured value is out of specification, adjust it to specification with cable adjusting nut.
    4.  
    5. With accelerator pedal depressed fully, check clearance between throttle lever and lever stopper (throttle body) which should measure 0.02-0.07 inch (0.5-2.0mm). If measured value is out of specification, adjust it to specification by changing height of pedal stopper bolt.
    6.  

  28.  
  29. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  30.  
  31. Refill engine with engine oil.
  32.  
  33. Refill cooling system.
  34.  
  35. Connect negative cable at battery.
  36.  
  37. Check ignition timing and adjust as necessary.
  38.  
  39. Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.
  40.  

 
label.common.footer.alt.autozoneLogo