Suzuki Vitara, Grand Vitara, XL7 2000-06

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system and engine oil.
  8.  
  9. Evacuate A/C system.
  10.  
  11. Remove or disconnect the following:

    Engine assembly from vehicle
     
    Camshafts, tappets and shims and RH (No.2) bank 2nd timing chain
     
    1st timing chain
     
    LH (No.1) bank 2nd timing chain
     
    Timing chain cover
     
    Oil pans and oil pump strainer
     
    Cylinder head covers
     
    Exhaust manifold
     
    Radiator outlet cap
     
    Intake manifold, intake collector and electric throttle body assembly
     

  12.  
  13. Loosen cylinder head bolts in numerical order (1-8).

    Cylinder head bolts
     
    Cylinder heads

    Click image to see an enlarged view

    Fig. Cylinder heads -2.7L

     

  14.  

To install:

  1. Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
  2.  
  3. Install knock pin to cylinder block.
  4.  
  5. Install new cylinder head gasket to cylinder block as shown in. Carved lot number on cylinder head gasket should face up (toward cylinder head side).

    Click image to see an enlarged view

    Fig. Head gasket Alignment

  6.  
  7. Install cylinder head to block.
  8.  
  9. After applying oil to cylinder head bolts, tighten them gradually as follows.
    1. Tighten cylinder head bolts (except hex hole bolt) to 38 ft. lbs. (53 Nm) according to numerical order.
    2.  
    3. In the same manner, tighten them to 61 ft. lbs. (84 Nm)
    4.  
    5. Loosen all bolts until tightening torque is reduced to 0 in reverse order of tightening.
    6.  
    7. In the same manner tighten them to 38 ft. lbs. (53 Nm).
    8.  
    9. In the same manner again, tighten them to 76 ft. lbs. (105 Nm).
    10.  
    11. Tighten cylinder head bolts (hex hole bolt) 7 ft. lbs. (11 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head numerical order-2.7L

    12.  

  10.  
  11. Check timing mark on crankshaft.
  12.  
  13. Install or connect the following:

    Water outlet cap
     
    Tappets, shims, camshafts, and RH (No.2) bank 2nd timing chain
     
    1st timing chain
     
    LH (No.1) bank 2nd timing chain
     
    Timing chain cover
     
    Oil pans and oil pump strainer
     
    Cylinder head covers
     
    Exhaust manifold
     
    Radiator outlet pipe
     
    Intake manifold, intake collector and electric throttle body assembly
     

  14.  
  15. Install engine assembly to vehicle.
  16.  
  17. Refill engine oil, cooling system, and any other fluids that may have been lost.
  18.  
  19. Vacuum and recharge A/C system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for leaks.
  24.  

1.6L Engine
  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:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake pipe
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust manifold heat shield
     
    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Exhaust manifold
     
    A/C compressor
     
    Power steering pump
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Camshaft timing sprocket
     
    Rear timing belt cover
     
    Distributor and spark plug wires, if equipped
     
    Ignition coils and wiring, if equipped with Distributorless Ignition System (DIS)
     
    Valve cover
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-1.6L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.6L engine

  1. Install the cylinder head with a new gasket.
  2.  
  3. For 1998 engines, tighten the bolts in sequence as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm)
    4.  
    5. Step 3: 52 ft. lbs. (70 Nm)
    6.  

  4.  
  5. For 1999-02 engines, tighten the bolts in sequence as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 26 ft. lbs. (35 Nm)
    8.  
    9. Step 5: 52 ft. lbs. (70 Nm)
    10.  

  6.  
  7. Install or connect the following:

    Valve cover
     
    Ignition coils and wiring, if equipped with DIS
     
    Distributor and spark plug wires, if equipped
     
    Rear timing belt cover
     
    Camshaft timing sprocket
     
    Timing belt
     
    Front cover
     
    Power steering pump
     
    A/C compressor
     
    Exhaust manifold
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Exhaust manifold heat shield
     
    HO 2 S sensor connectors
     
    Intake manifold
     
    Intake manifold brackets
     
    Alternator bracket
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    Air intake pipe
     
    Accessory drive belts
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

  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:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake pipe
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust manifold heat shield
     
    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Exhaust manifold
     
    A/C compressor
     
    Power steering pump
     
    Front cover
     
    Timing belt
     
    Camshaft timing sprocket
     
    Rear timing belt cover
     
    Distributor and spark plug wires, if equipped
     
    Ignition coils and wiring, if equipped with Distributorless Ignition System (DIS)
     
    Valve cover
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-1.6L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.6L engine

  1. Install the cylinder head with a new gasket.
  2.  
  3. Tighten the bolts in sequence as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: 41 ft. lbs. (55 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 26 ft. lbs. (35 Nm)
    8.  
    9. Step 5: 52 ft. lbs. (70 Nm)
    10.  

  4.  
  5. Install or connect the following:

    Valve cover
     
    Ignition coils and wiring, if equipped with DIS
     
    Distributor and spark plug wires, if equipped
     
    Rear timing belt cover
     
    Camshaft timing sprocket
     
    Timing belt
     
    Front cover
     
    Power steering pump
     
    A/C compressor
     
    Exhaust manifold
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Exhaust manifold heat shield
     
    HO 2 S sensor connectors
     
    Intake manifold
     
    Intake manifold brackets
     
    Alternator bracket
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    Air intake pipe
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

1.8L 2.0L Engines
  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. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower brace
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emission (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Camshaft Position (CMP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Fuel injector connectors
     
    Ignition coils
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Radiator hose
     
    Bypass hose
     
    Heater hose
     
    Fuel lines
     
    Intake manifold bracket
     
    Water pipe
     
    Valve cover
     
    Accessory drive belts
     
    Oil pan
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-1.8L and 2.0L engines

     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.8L and 2.0L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. For 1.8L engines, tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 27 ft. lbs. (37 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  4.  
  5. For 2.0L engines, tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  6.  
  7. Install or connect the following:

    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Camshafts
     
    Timing chains
     
    Front cover
     
    Oil pan
     
    Accessory drive belts
     
    Valve cover
     
    Water pipe
     
    Intake manifold bracket
     
    Fuel lines
     
    Heater hose
     
    Bypass hose
     
    Radiator hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Ignition coils
     
    Fuel injector connectors
     
    ECT sensor connector
     
    CMP sensor connector
     
    HO 2 S sensor connectors
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Strut tower brace
     
    Negative battery cable
     

  8.  
  9. Fill the crankcase to the correct level.
  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
  14.  

2.0L Engine
  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. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower brace
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emission (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Camshaft Position (CMP) sensor connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Fuel injector connectors
     
    Ignition coils
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Radiator hose
     
    Bypass hose
     
    Heater hose
     
    Fuel lines
     
    Intake manifold bracket
     
    Water pipe
     
    Valve cover
     
    Accessory drive belts
     
    Oil pan
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Exhaust front pipe
     
    Exhaust manifold bracket
     
    Cylinder head. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.0L engines

     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.0L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. Tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  4.  
  5. Install or connect the following:

    Exhaust manifold bracket
     
    Exhaust front pipe
     
    Camshafts
     
    Timing chains
     
    Front cover
     
    Oil pan
     
    Accessory drive belts
     
    Valve cover
     
    Water pipe
     
    Intake manifold bracket
     
    Fuel lines
     
    Heater hose
     
    Bypass hose
     
    Radiator hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Ignition coils
     
    Fuel injector connectors
     
    ECT sensor connector
     
    CMP sensor connector
     
    HO 2 S sensor connectors
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Strut tower brace
     
    Negative battery cable
     

  6.  
  7. Fill the crankcase to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

2.5L Engine
  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 and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Ignition coil covers and ignition coils
     
    Valve covers
     
    Oil pan
     
    Timing chain cover and timing chains
     
    Camshaft Position (CMP) sensor
     
    Camshafts
     
    Exhaust manifolds
     
    Water outlet caps
     
    Cylinder heads. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.5L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L engine

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  2.  
  3. Install or connect the following:

    Water outlet caps
     
    Exhaust manifolds
     
    Camshafts
     
    CMP sensor
     
    Timing chain cover and timing chains
     
    Oil pan
     
    Valve covers
     
    Ignition coil covers and ignition coils
     
    Intake manifold
     
    Negative battery cable
     

  4.  
  5. Fill the crankcase to the correct level
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

2.5L, 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Ignition coil covers and ignition coils
     
    Valve covers
     
    Oil pan
     
    Timing chain cover and timing chains
     
    Camshaft Position (CMP) sensor
     
    Camshafts
     
    Exhaust manifolds
     
    Water outlet caps
     
    Cylinder heads. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.5L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L engine

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 38 ft. lbs. (52 Nm)
    2.  
    3. Step 2: 61 ft. lbs. (84 Nm)
    4.  
    5. Step 3: Loosen all bolts to 0 ft. lbs. (0 Nm)
    6.  
    7. Step 4: 38 ft. lbs. (52 Nm)
    8.  
    9. Step 5: 76 ft. lbs. (105 Nm)
    10.  
    11. Step 6: 6mm bolt to 96 inch lbs. (8 Nm)
    12.  

  2.  
  3. Install or connect the following:

    Water outlet caps
     
    Exhaust manifolds
     
    Camshafts
     
    CMP sensor
     
    Timing chain cover and timing chains
     
    Oil pan
     
    Valve covers
     
    Ignition coil covers and ignition coils
     
    Intake manifold
     
    Negative battery cable
     

  4.  
  5. Fill the crankcase to the correct level
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

 
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