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Home >> Suzuki >> 2002 >> XL-7 Plus >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.7L V6 >> Repair Instructions >> Engine Assembly Removal & Installation >> Removal
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Engine Assembly Removal & Installation: Removal

  1. Release fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE .
  2. Disconnect negative (-) cable at battery.
  3. Remove engine hood.
  4. Drain engine oil.
  5. Drain coolant referring to COOLANT DRAINING .
  6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to COOLING FAN & FAN CLUTCH REMOVAL & INSTALLATION and RADIATOR REMOVAL & INSTALLATION .
  7. Disconnect accelerator cable from throttle body.
    Fig 1: Disconnecting Accelerator Cable From Throttle Body
    G02264068Courtesy of SUZUKI OF AMERICA CORP.
  8. Detach fuse/relay box, then remove strut tower bar and surge tank cover.
  9. Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.
  10. Remove intake control valve , referring to THROTTLE BODY REMOVAL & INSTALLATION .
  11. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
  12. Remove ignition coil covers.
  13. Disconnect the following electric lead wires:
    • Injector wire coupler
    • CMP sensor coupler
    • Ignition coil couplers
    • CKP sensor coupler
    • MAP sensor coupler
    • TP sensor (1) coupler
    • IAC valve (2) coupler
    • Earth wire (3) from surge tank
    • EVAP canister purge valve (5) coupler
    • EGR valve (6) coupler
    • Oxygen sensor-1 and -2 couplers (Refer to EXHAUST MANIFOLD REMOVAL & INSTALLATION .)
    • Coolant temperature sensor coupler
    • Knock sensor coupler
    • Generator wires
    • Starter wires
    • Oil pressure wire
    • P/S pump wire
    • Earth wire from generator bracket
    • Engine block heater (if equipped)
  14. Remove clamps and brackets (4).
  15. Disconnect the following hoses:
    • Heater hose (7) from heater water pipe and water outlet cap
    • Tank pressure control solenoid valve hose from intake manifold
    • EVAP canister hose from canister purge pipe
    • Brake booster vacuum hose
  16. Remove EVAP canister purge valve (5).
    Fig 2: Locating Connectors
    G02264069Courtesy of SUZUKI OF AMERICA CORP.
  17. Disconnect the following hoses at the location shown in the figure:
    • Fuel feed hose (1) from fuel feed pipe
    • Fuel return hose (2) from fuel return pipe
    Fig 3: Locating Hoses
    G02264070Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove P/S pump assembly referring to P/S PUMP REMOVAL & INSTALLATION .
  19. Remove A/C compressor assembly. Refer to COMPRESSOR ASSEMBLY REMOVAL & INSTALLATION .
  20. Remove steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY REMOVAL & INSTALLATION .
  21. Raise vehicle.
  22. Remove front differential housing with differential from chassis if equipped. Refer to FRONT DIFFERENTIAL DISMOUNTING & REMOUNTING .
  23. Remove exhaust No. 1 pipe referring to EXHAUST MANIFOLD REMOVAL & INSTALLATION .
  24. Remove exhaust manifold stiffener from transmission.
  25. Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)
    Fig 4: Removing A/T Fluid Hose Clamps From Engine Mounting Bracket (A/T Only)
    G02264071Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove clutch housing lower plate.
  27. Remove torque converter bolts (for A/T vehicle).
  28. Remove starter motor.
  29. Lower vehicle.
  30. Support transmission.
    CAUTION: Do not support A/T by placing jacking equipment under oil pan. It may damage A/T.
  31. Remove bolts and nuts fastening cylinder block and transmission.
    Fig 5: Removing Bolts & Nuts Fastening Cylinder Block & Transmission
    G02264072Courtesy of SUZUKI OF AMERICA CORP.
  32. Install lifting device.
  33. Disconnect engine side mounting brackets (1) from engine mountings (2) by removing nuts (3).
    Fig 6: Disconnecting Engine Side Mounting Brackets
    G02264073Courtesy of SUZUKI OF AMERICA CORP.
  34. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
  35. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.
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