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Engine Assembly Removal & Installation: Removal

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure in fuel line. See RELIEVING FUEL PRESSURE .
  2. Disconnect negative cable at battery.
  3. Remove engine hood.
  4. Remove strut tower bar (1).
    Fig 1: Identifying Engine Hood & Strut Tower Bar Fasteners
    G01351976Courtesy of SUZUKI OF AMERICA CORP.
  5. Drain coolant.
    Fig 2: Identifying Radiator Coolant Drain Plug
    G01351977Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove radiator, radiator fan shroud and cooling fan. See COOLING FAN AND FAN CLUTCH REMOVAL & INSTALLATION .
  7. Remove air cleaner outlet hose.
  8. Disconnect the following electric lead wires:
    • Injector wire harness coupler
    • CMP sensor coupler
    • Ignition coil couplers
    • TP sensor coupler
    • MAF sensor coupler
    • IAT sensor coupler
    • IAC valve coupler
    • Ground wire from intake manifold
    • EVAP canister purge valve coupler
    • EGR valve coupler
    • Heated oxygen sensor-1 and/or-2 wire
    • ECT sensor coupler
    • Generator wires
    • Starter wires
    • Oil pressure switch wire
    • Power steering pressure switch wire
    • Wire harness clamps
    • MAP sensor
    • CKP sensor
    • EVAP canister air valve
    • Tank pressure control solenoid valve
    • Engine block heater (if equipped)
    Fig 3: Identifying Peripheral Engine Components
    G01351978Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove starter motor.
  10. Disconnect accelerator cable and A/T throttle cable (for A/T vehicle) from throttle body.
  11. Disconnect the following hoses:
    • Fuel feed hose and return hose from each pipe
    • Heater hoses from heater core
    • Vacuum hose from intake manifold
    • Brake booster vacuum hose
    Fig 4: Identifying Engine Hoses
    G01351979Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove EVAP canister from vehicle body.
  13. With hoses connected, detach power steering pump and A/C compressor from cylinder block if equipped.
    Fig 5: Identifying Power Steering Pump & A/C Compressor
    G01351980Courtesy of SUZUKI OF AMERICA CORP.
  14. Raise vehicle.
  15. Drain engine oil if necessary.
  16. Remove front differential housing with differential from chassis. See FRONT DIFFERENTIAL DISMOUNTING & REMOUNTING .
  17. Remove exhaust pipe bolt or exhaust No. 1 pipe (1).
    Fig 6: Identifying Front Exhaust Components
    G01351981Courtesy of SUZUKI OF AMERICA CORP.
  18. Release A/T fluid hoses from clamps (for A/T vehicle).
  19. Remove right side transmission stiffener (1) (if equipped).
    Fig 7: Identifying Right Side Transmission Stiffener
    G01351982Courtesy of SUZUKI OF AMERICA CORP.
  20. Remove clutch housing lower plate.
  21. Remove torque converter bolts (for A/T vehicle).

    Special tool 

    1. (A):  09927-56010
    Fig 8: Identifying Special Tool (A)
    G01351983Courtesy of SUZUKI OF AMERICA CORP.
  22. Lower vehicle
  23. Support transmission. For A/T vehicle, don't jack under A/T oil pan to support transmission.
  24. Remove bolt and nuts fastening cylinder block and transmission.
    Fig 9: Identifying Upper Cylinder Block & Transmission Fasteners
    G01351984Courtesy of SUZUKI OF AMERICA CORP.
  25. Install lifting device (2).
  26. Remove engine side mounting bracket nuts (1) from vehicle mountings.
  27. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
  28. Remove engine assembly from chassis and transmission by lifting a little, sliding toward front, and then, carefully hoist engine assembly.
    Fig 10: Identifying Lifting Device & Engine Side Mounting Bracket Nuts
    G01351985Courtesy of SUZUKI OF AMERICA CORP.
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