Suzuki GRAND VITARA 2005 Service Manual page 204
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Also See for GRAND VITARA 2005:
- Owner's manual (1736 pages) ,
- Service manual (801 pages) ,
- Manual (35 pages)
Table of Contents
1D-41 Engine Mechanical:
Installation
1) Remove oil, old sealant and dust from bolt holes and
mating surface of cylinder head and cylinder block.
2) Install camshaft and tappets referring to "Camshaft
and Tappet Removal and Installation: ", if removed.
3) Install cylinder head cover referring to "Cylinder
Head Cover Removal and Installation: ", if removed.
4) Install injection pump referring to "Injection Pump
Removal and Installation: in Section 1G", if
removed.
5) Install common rail (high pressure fuel injection rail)
referring to "Common Rail (High Pressure Fuel
Injection Rail) Removal and Installation: in Section
1G", if removed.
6) Install fuel injector referring to "Fuel Injector Removal
and Installation: in Section 1G", if removed.
7) Install high pressure pipes referring to "High
Pressure Pipe Removal and Installation: in Section
1G", if removed.
8) Install intake and exhaust manifolds referring to
"Intake Manifold and Exhaust Manifold Removal and
Installation: ", if removed.
9) Install vacuum pump referring to "Vacuum Pump
Removal and Installation: ", if removed.
10) Install thermostat assembly referring to "Thermostat
Assembly Removal and Installation: in Section 1F",
if removed.
11) Install dowel pins (1) to cylinder block, if removed.
12) Install new cylinder head gasket (2) to cylinder block.
13) Install cylinder head to cylinder block, and tighten
new cylinder head bolts as follows.
a) Tighten cylinder head bolts to 30 N⋅m (3.0 kgf-m,
22.0 lb-ft) according to numerical order ("1"
through "10") as shown in figure.
b) Retighten them by turning through 100° in same
manner as Step a).
c) Wait 3 minutes for setting time.
d) Loosen cylinder head bolts ("1" and "2") until they
are completely free, and tighten them to 25 N⋅m
(2.5 kgf-m, 18.0 lb-ft), then retighten then by
turning through 213°.
e) Loosen and tighten bolts ("3" and "4"), bolts ("5"
and "6"), bolts ("7" and "8") then bolt ("9" and
"10") in the same manner as Step d).
Tightening torque
Cylinder head bolt (a): Tighten 30 N⋅m (3.0
kgf-m, 22.0 lb-ft), 100°, 0 N⋅m (0.0 kgf-m, 0.0
lb-ft), 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and 213°
by the specified procedure
14) Install injection pump rear bracket referring to
"Injection Pump Removal and Installation: in Section
1G", if necessary.
15) Install EGR valve referring to "EGR Valve Removal
and Installation: ".
16) Install oil separator referring to "Oil Separator
Removal and Installation: ".
17) Install EGR cooler referring to "EGR Pipe and EGR
Cooler Removal and Installation: ".
18) Install turbocharger referring to "Turbocharger
Assembly Removal and Installation: ".
19) Install ventilation pipe No.2 referring to "Oil
I5JB0B140078-01
Separator Components: ".
20) Install timing belt referring to "Timing Belt and Belt
Tensioner Removal and Installation: ".
21) Install engine assembly referring to "Engine
Assembly Removal and Installation: ".
I5JB0B140079-01
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