Suzuki Forenza, Reno 2003-06
Cylinder Head
· REMOVAL & INSTALLATION
Removal & Installation
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. Remove the fuel pump fuse.
3. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
4. Disconnect the negative battery cable.
5. Disconnect the Engine Control Module (ECM) ground terminal.
6. Drain the engine coolant.
7. Remove or disconnect the following:
Manifold Air Temperature (MAT) sensor connector
Breather tube from the camshaft cover
Air cleaner outlet hose from the throttle body
Direct Ignition System (DIS) coil connector
Oxygen (O2) sensor connector
Electronic Throttle Control (ETC) connector
Engine Coolant Temperature (ECT) sensor connector
Coolant Temperature Sensor (CTS) connector
Remove the air cleaner housing bolts and air cleaner housing
Right front wheel
Right front wheel well splash shield
8. Install the engine assembly support fixture DW110-060.
Right engine mount bracket and bolts
Upper radiator hose at the thermostat housing
Serpentine drive belt
Crankshaft pulley bolts and crankshaft pulley
Front timing belt cover bolts and front timing belt cover
Timing belt
Breather tube at the camshaft cover
Spark plug cover bolts and spark plug cover
Ignition wires from the spark plugs
Camshaft cover bolts, camshaft cover and camshaft cover gasket
Intake camshaft gear bolt, while holding intake camshaft firmly in place
Intake camshaft gear
Exhaust camshaft gear bolt, while holding exhaust camshaft firmly in place
Exhaust camshaft gear
Timing belt automatic tensioner bolts and timing belt automatic tensioner
Timing belt idler pulley bolt and nut and timing belt idler pulleys
Engine mount bolts and engine mount
Crankshaft gear
CMP sensor
Water pump
Rear timing belt cover bolts and rear timing belt cover
Exhaust flex pipe retaining nuts at the exhaust manifold studs
All of the necessary vacuum hoses
Fuel feed line at the fuel rail
Alternator adjusting bracket retaining bolt and the bracket
Coolant hose at the rear cylinder head and ignition coil Exhaust Gas Recirculation (EGR) bracket
Surge tank coolant hose at the throttle body
Fuel rail assembly
Alternator-to-intake manifold support bracket bolts at cylinder head and intake manifold
Alternator support bracket
Intake manifold-to-generator strap bracket bolt and loosen bolt on alternator
Move the strap clear of the intake manifold.
Charcoal Canister Purge (CCP) and EGR solenoid bracket bolt and move bracket clear
Throttle cable at throttle body and intake manifold
Loosen all cylinder head bolts gradually and in reverse order of tightening
Camshafts
Cylinder head bolts
Cylinder head with intake manifold and exhaust manifold attached
Cylinder head gasket
9. Clean the cylinder block and cylinder head mating surfaces of any old gasket material, oil or dust and clean any engine coolant from the cylinders.
To install:
Fig. Cylinder head bolt tightening sequence-2.0L engine
1. Install or connect the following:
New cylinder head gasket
Cylinder head with intake manifold and exhaust manifold attached
Cylinder head bolts. Tighten the cylinder head bolts gradually and in the sequence shown. Tighten the cylinder head bolts to 18 ft. lbs. (25 Nm) and turn the bolts another 3 turns of 90 degrees using the angular torque gauge KM-470-B.
Camshafts
Throttle cable at throttle body and intake manifold
Alternator-to-intake manifold support bracket
Alternator-to-intake manifold support bracket bolts and tighten to 27 ft. lbs. (37 Nm)
Intake manifold support bracket bolt to alternator and tighten to 16 ft. lbs. (22 Nm)
Surge tank coolant hose at throttle body
Coolant hose to rear cylinder head and ignition coil EGR bracket
Fuel feed line at the fuel rail
Fuel return line at the fuel rail
All necessary vacuum hoses
Fuel rail assembly
Exhaust flex pipe retaining nuts at the exhaust manifold studs and tighten to 26 ft. lbs. (35 Nm)
Rear timing belt cover. Tighten the rear timing belt cover bolts to 62 inch lbs. (7 Nm).
Engine mount and retaining bolts. Tighten the engine mount retaining bolts to 33 ft. lbs. (45 Nm).
CMP sensor
Crankshaft gear
Water pump
Timing belt automatic tensioner. Tighten the timing belt automatic tensioner bolts to 18 ft. lbs. (25 Nm).
Timing belt idler pulleys, bolt and nut. Tighten the timing belt idler pulley bolt to 18 ft. lbs. (25 Nm).
Camshaft gears with the timing marks at the front
Guide pin of the intake camshaft into -IN- bore
Guide pin of the exhaust camshaft into -EX- bore
Camshaft gears by counterholding on the hex of the camshaft with an open-ended wrench
Intake camshaft gear with a new bolt to the camshaft. Tighten the intake camshaft gear bolt to 37 ft. lbs. (50 Nm) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge.
Exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place. Tighten the exhaust camshaft gear bolt to 37 ft. lbs. (50 Nm) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge.
Small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover-to-cylinder head seal
Camshaft cover, gasket and washers
Camshaft cover bolts and tighten to 71 inch lbs. (8 Nm)
Ignition wires to the spark plugs
Spark plug cover and tighten the spark plug cover bolts to 71 inch lbs. (8 Nm)
Breather tube to the camshaft cover
Timing belt
Front timing belt cover
Crankshaft pulley. Tighten the crankshaft pulley bolts to 106 inch lbs. (12 Nm).
Right engine mount bracket. Tighten the engine mount bracket retaining bolts to 41 ft. lbs. (55 Nm).
2. Remove the engine assembly lift support DW110-060.
Serpentine drive belt
Upper radiator hose to thermostat housing
Right front wheel well splash shield
Right front wheel
Air cleaner housing
Air cleaner outlet hose to the throttle body
Breather tube to the camshaft cover
MAT sensor connector
CTS connector
Engine CTS connector
ETC connector
CCP and EGR solenoid bracket bolt and tighten to 44 inch lbs. (5 Nm)
DIS coil connector
O2 sensor connector
ECM ground terminal
Fuel pump fuse
3. Refill the engine cooling system.
4. Connect the negative battery cable.
5. Start the engine and check for leaks.