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Removal Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the battery box and carefully set the engine control module (ECM) on top of the engine. Refer to REMOVAL PROCEDURE .
  2. Disconnect the ECM connector from the under-hood fuse block.
  3. Disconnect ground wire from frame, near battery box.
  4. Remove the fuel injector sight shield. Refer to REMOVAL PROCEDURE .
  5. Release the clamp from the brake booster vacuum hose connection.
  6. Disconnect the brake booster vacuum hose from the intake manifold.
  7. Remove the air cleaner assembly. Refer to REMOVAL PROCEDURE .
  8. Discharge the fuel system. Refer to FUEL PRESSURE RELIEF (WITH J 34730-1A) and FUEL PRESSURE RELIEF (WITHOUT J 34730-1A) .
  9. Disconnect the evaporative emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  10. Disconnect the engine fuel hose/pipe from the chassis fuel hose/pipe. Refer to METAL COLLAR QUICK CONNECT FITTING SERVICE .
  11. Discharge the air conditioning (A/C) system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  12. Remove the A/C compressor hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT .
  13. Disconnect the transaxle shift control cable from the transaxle. Refer to REMOVAL PROCEDURE .
  14. Drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL) and DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL) .
  15. Tie the radiator, A/C condenser, and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame and drivetrain is removed.
  16. Disconnect the heater hoses from the engine. Refer to HEATER OUTLET HOSE REPLACEMENT .
  17. Remove the radiator inlet hose. Refer to RADIATOR INLET HOSE REPLACEMENT .
  18. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  19. Remove the radiator outlet hose. Refer to RADIATOR OUTLET HOSE REPLACEMENT .
    Fig 1: Disconnecting Transaxle Oil Cooler Lines From Transaxle
    G04841603Courtesy of SUZUKI OF AMERICA CORP.
  20. Disconnect the transaxle oil cooler lines from the transaxle and remove the seals. Refer to REMOVAL PROCEDURE .
  21. Cap the transaxle oil cooler lines and plug the transaxle oil cooler line fittings to prevent loss of transmission fluid.
  22. Remove the catalytic converters and secure the rear half of the exhaust system to the vehicle underbody. Refer to REMOVAL PROCEDURE and REMOVAL PROCEDURE .
  23. Remove the front tires. Refer to REMOVAL PROCEDURE .
  24. Remove the right and left engine splash shields. Refer to ENGINE SPLASH SHIELD REPLACEMENT - LEFT SIDE and ENGINE SPLASH SHIELD REPLACEMENT - RIGHT SIDE .
    Fig 2: Identifying Steering Intermediate Shaft Pinch Bolt
    G04841604Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove the steering intermediate shaft pinch bolt and discard the bolt.
  26. Disconnect the steering intermediate shaft from the steering gear.
    Fig 3: Identifying Outer Tie Rod Ends
    G04841605Courtesy of SUZUKI OF AMERICA CORP.
  27. Remove the right and left outer tie rod ends from the steering knuckles. Refer to RACK AND PINION OUTER TIE ROD END REPLACEMENT .
    Fig 4: Identifying Stabilizer Shaft Links
    G04841606Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove the right and left stabilizer shaft links from the stabilizer shaft. Refer to STABILIZER SHAFT LINK REPLACEMENT .
    Fig 5: Removing Lower Ball Joints From Steering Knuckles
    G04841607Courtesy of SUZUKI OF AMERICA CORP.
  29. Remove the right and left lower ball joints from the steering knuckles. Refer to REMOVAL PROCEDURE .
  30. On front wheel drive (FWD) models, place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle. Refer to REMOVAL PROCEDURE and REMOVAL PROCEDURE .
  31. On all wheel drive (AWD) models, remove the rear wheel driveshaft. Refer to REMOVAL PROCEDURE .
    Fig 6: Placing Block Of Wood Between Frame & Engine Oil Pan
    G04841608Courtesy of SUZUKI OF AMERICA CORP.
  32. On all models, place a block of wood (1) between the frame and the engine oil pan in order to support the engine once the bolts are removed from the right engine mount.
    Fig 7: Removing Right Engine Mount To Engine
    G04841609Courtesy of SUZUKI OF AMERICA CORP.
  33. Lower the vehicle.
  34. Remove the bolts (2) that secure the right engine mount (1) to the engine (3).
    NOTE: Insure the vehicle body is secured to the hoist.
  35. Raise the vehicle.
  36. Place a universal frame support fixture or jackstands under the frame.
  37. Lower the vehicle until the frame contacts the frame support fixture or jackstands.
  38. Disconnect the wiring harness retaining clips near the right and left shock towers.
  39. Remove the drivetrain and front suspension frame reinforcement. Refer to REMOVAL PROCEDURE .
    Fig 8: Identifying Frame-To-Body Bolts
    G04841610Courtesy of SUZUKI OF AMERICA CORP.
  40. Remove the frame-to-body bolts. Discard the bolts.
    NOTE: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.
  41. Carefully raise the vehicle body up away from the powertrain.
    Fig 9: Disconnecting Engine Electrical Wiring Harness
    G04841611Courtesy of SUZUKI OF AMERICA CORP.
  42. Disconnect the engine electrical wiring harness from the following components:
    • Oxygen sensor (1)
    • EVAP purge solenoid (2)
    • Ignition coils (3, 4, 10)
    • Ground leads (7, 11)
    • Remove wire harness from retainers (5, 6, 8, 9)
      Fig 10: Disconnecting Cylinder Head Engine Electrical Wiring Harness
      G04841612Courtesy of SUZUKI OF AMERICA CORP.
  43. Disconnect the left and right cylinder head engine electrical wiring harness from the following components:
    • Camshaft position sensors (1)
    • Camshaft position actuators (2)
      Fig 11: Disconnecting Engine Wiring Harness Electrical Connector
      G04841613Courtesy of SUZUKI OF AMERICA CORP.
  44. Disconnect the engine electrical wiring harness from the following components:
    • Generator (1)
    • Retainer clips (2, 3, 4, 5, 6, 7, 9)
    • A/C compressor hose (8)
    • Oil pressure switch (10)
    • A/C compressor (8)
      Fig 12: Disconnecting Engine Wiring Harness Electrical Connector
      G04841614Courtesy of SUZUKI OF AMERICA CORP.
  45. Disconnect the engine electrical wiring harness from the following components:
    • Battery cable (1)
    • Retainer clips (2, 3)
    • Transmission module (4)
      Fig 13: Identifying Engine Coolant Heater
      G04841615Courtesy of SUZUKI OF AMERICA CORP.
  46. If equipped with an engine coolant heater, disconnect the coolant heater cord.
  47. Remove the throttle body assembly. Refer to REMOVAL PROCEDURE .
    Fig 14: Removing Engine-To-Transaxle Brace Bolts
    G04841616Courtesy of SUZUKI OF AMERICA CORP.
  48. Remove the engine-to-transaxle brace bolts (1, 2) and brace (3).
  49. Remove the starter motor. Refer to REMOVAL PROCEDURE .
    Fig 15: Removing Torque Converter Bolts
    G04841617Courtesy of SUZUKI OF AMERICA CORP.
  50. Remove the torque converter bolts.
  51. Install the engine support adapters to the engine. Refer to INSTALLATION PROCEDURE .
  52. Support the engine weight with an engine hoist.
    Fig 16: Separating Automatic Transaxle From Engine
    G04841618Courtesy of SUZUKI OF AMERICA CORP.
  53. Remove the automatic transaxle bolts.
  54. Separate the automatic transaxle from the engine.
  55. Lift the engine away from the frame and the automatic transaxle.
  56. Secure the engine to an engine stand.
  57. Remove any additional engine components as necessary. Refer to appropriate component sections in manual if needed.
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