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Home >> Suzuki >> 2002 >> XL-7 Plus >> Repair and Diagnosis >> External Pages >> Different car >> Section 153 (Engine Mechanical) >> Repair Instructions >> Engine Assembly Removal and Installation >> Removal
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Engine Assembly Removal and Installation: Removal

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure in fuel feed line. Refer to "FUEL PRESSURE RELIEF PROCEDURE ".
  2. Disconnect negative cable at battery.
  3. Remove engine hood.
  4. Drain engine oil.
  5. Drain coolant.
  6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to "RADIATOR REMOVAL AND INSTALLATION " and "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION .
  7. Disconnect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) from throttle body.
    Fig 1: Disconnecting Accelerator Cable & A/T Throttle Cable (For A/T Vehicle)
    G02256856Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove strut tower bar and surge tank cover.
  9. Disconnect IAT sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.
  10. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
  11. Remove ignition coil covers.
  12. Disconnect the following electric lead wires:
    • Injector wire coupler
    • CMP sensor coupler
    • Ignition coil couplers
    • CKP sensor coupler
    • TP sensor coupler (1)
    • MAF sensor coupler (2)
    • IAC valve coupler (3)
    • Earth wire (4) from surge tank
    • EVAP canister purge valve coupler (6)
    • EGR valve (8) coupler
    • Oxygen sensor-1 and -2 couplers (Refer to "EXHAUST MANIFOLD REMOVAL AND INSTALLATION " for disconnection.)
    • Coolant temperature sensor coupler
    • Generator wires
    • Starter wires
    • Oil pressure wire
    • P/S pump wire
    • Earth wire from generator bracket
    • Engine block heater (if equipped)
  13. Remove clamps and brackets (5).
  14. Disconnect the following hoses:
    • Heater hoses (9) from heater water pipe and water outlet cap
    • Brake booster vacuum hose
    • EVAP canister hose from canister pipe
    • Tank pressure control solenoid valve hose from intake manifold
  15. Remove IAC valve (7) and EVAP canister purge valve (6).
    Fig 2: Removing IAC Valve & EVAP Canister Purge Valve
    G02256857Courtesy of SUZUKI OF AMERICA CORP.
  16. 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: Disconnecting Fuel Feed Hose & Return Hose
    G02256858Courtesy of SUZUKI OF AMERICA CORP.
  17. Remove EVAP canister.
  18. Remove P/S pump assembly. Refer to "POWER STEERING PUMP REMOVAL AND INSTALLATION .
  19. Remove A/C compressor assembly. Refer to "COMPRESSOR REMOVAL AND INSTALLATION ".
  20. Remove steering shaft lower assembly. Refer to "STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION ".
  21. Raise vehicle.
  22. Remove front differential housing with differential from chassis if equipped. Refer to "FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING ".
  23. Remove exhaust No. 1 pipe. Refer to "EXHAUST MANIFOLD REMOVAL AND INSTALLATION ".
  24. Remove exhaust manifold stiffener from transmission referring to "EXHAUST MANIFOLD REMOVAL AND INSTALLATION ".
  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
    G02256859Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove clutch housing lower plate.
  27. Remove torque converter bolts (for A/T vehicle).
  28. Remove starter motor referring to "REMOVAL & INSTALLATION ".
  29. Lower vehicle.
  30. Support transmission. For A/T vehicle, don't jack under A/T oil pan to support transmission.
  31. Remove bolts and nuts fastening cylinder block and transmission.
    Fig 5: Removing Bolts & Nuts Fastening Cylinder Block & Transmission
    G02256860Courtesy of SUZUKI OF AMERICA CORP.
  32. Install lifting device.
  33. Disconnect engine side mounting brackets (1) to engine mountings.
    Fig 6: Disconnecting Engine Side Mounting Brackets
    G02256861Courtesy 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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