Suzuki Vitara, Grand Vitara, XL7 2000-06

Camshaft (Cylinder Head) Cover

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Removal & Installation



1.6L Engine
  1. Disconnect negative cable at battery.
  2.  
  3. Remove ignition coil assemblies with high-tension cord.
  4.  
  5. Disconnect PCV valve and breather hose from head cover.
  6.  
  7. Detach accelerator cable from clamp.
  8.  
  9. Remove cylinder head cover with camshaft cover gasket and O-rings.
  10.  

To install:

  1. Install O-rings and camshaft cover gasket to cylinder head cover.
  2.  
  3. Install camshaft cover to cylinder head and tighten cover bolts to 8 ft. lbs. (11 Nm).
  4.  
  5. Fix accelerator cable with clamp.
  6.  
  7. Install ignition coil assemblies with high-tension cord.
  8.  
  9. Connect PCV valve and breather hose to head cover.
  10.  
  11. Connect negative cable at battery.
  12.  

2.0L Engine
  1. Disconnect negative cable at battery.
  2.  
  3. Disconnect ignition coil couplers.
  4.  
  5. Remove ignition coils.
  6.  
  7. Disconnect accelerator cable from clamp (For LH steering vehicle only).
  8.  
  9. Remove oil level gauge.
  10.  
  11. Disconnect breather hose and PCV hose from cylinder camshaft cover.
  12.  
  13. Remove camshaft cover.
  14.  

To install:

  1. Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant to cylinder head sealing surface areas.
  2.  
  3. Install cylinder head side seal and camshaft cover to cylinder head.
  4.  
  5. Tighten nuts a little at a time till they are tightened to 8 ft. lbs. (11 Nm).
  6.  
  7. Use new seal washers.
  8.  
  9. Install ignition coils and connect ignition coil couplers.
  10.  
  11. Install oil level gauge.
  12.  
  13. Connect breather hose and PCV hose to cylinder head cover.
  14.  
  15. Connect accelerator cable to clamp (For LH steering vehicle only).
  16.  
  17. Connect the negative battery cable.
  18.  

2.5L, 2.7L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove throttle body and intake manifold.
  4.  
  5. Remove ignition coil covers.
  6.  
  7. Remove camshaft covers.
  8.  
  9. Clean sealing surfaces on cylinder heads and covers.
  10.  
  11. Remove oil, old sealant, and dust from sealing surfaces. After cleaning, apply sealant A to cylinder heads sealing surface area as shown in figure.

    Click image to see an enlarged view

    Fig. sealant surface area A

  12.  

To install:

  1. Install new camshaft cover gaskets to camshaft covers.
  2.  
  3. Install camshaft covers to cylinder heads.
  4.  
  5. Using new seal washers, tighten nuts to 7.5 ft. lbs. (10.5 Nm).
  6.  
  7. Install ignition coils and connect ignition coil couplers.
  8.  
  9. Install ignition coil covers.
  10.  
  11. Install intake manifold with throttle body.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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