Valve Cover: Service and Repair

Cylinder Head Cover Removal and Installation

Removal
1. Disconnect negative (-) cable at battery.
2. Remove ignition coils.
3. Remove oil level gauge (1).
4. Disconnect CMP sensor connector (2) and then remove CMP sensor (7) from cylinder head cover.
5. Disconnect breather hose (3) and PCV hose (4) from cylinder head cover (5).
6. Remove harness bracket (6) from cylinder head cover (5).





7. Remove PCV valve from cylinder head cover.
8. Remove cylinder head cover nuts in such order as indicated in the figure.





9. Remove cylinder head cover from cylinder head.
10. Remove cylinder head side seals from cylinder head.

Installation
1. Install PCV valve to cylinder head cover.
2. Remove oil, old sealant and dust from sealing surfaces on cylinder head and cover.
3. Install new cylinder head side seals (1) to cylinder head.
4. Apply sealant "A" to cylinder head sealing surface area as shown in figure.
"A": Water tight sealant 99000-31250SUZUKI Bond No.1207F





5. Apply engine oil to new O-rings.
6. Install new O-rings. (3) and new cylinder head cover gasket (2) to cylinder head cover (1).

NOTE: Be sure to check each of these parts for deterioration or any damage before installation and replace if found defective.

7. Install cylinder head cover to cylinder head.





8. Tighten cylinder head cover nuts in such order as indicated in the figure a little at a time till they are tightened to specified torque.
^ Use new seal washers.

Tightening torque
Cylinder head cover nut a: Tighten 11 Nm (1.1 kgf-m, 8.0 ft. lbs.) by the specified procedure





9. Install oil level gauge (1).
10. Install CMP sensor (5) to cylinder head cover.
11. Connect CMP sensor connector (4).
12. Connect breather hose (2) and PCV hose (3) to cylinder head cover.
13. Install harness bracket (6) to cylinder head cover.





14. Install ignition coils.
15. Install air cleaner case.
16. Connect negative (-) cable at battery.