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Home >> Suzuki >> 2004 >> Aerio LX, FWD, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical >> Repair Instructions >> Engine Assembly Removal and Installation. >> Installation
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Engine Assembly Removal and Installation.: Installation

  1. Install clutch cover and clutch disk. Refer to CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL (M/T).
  2. Connect transaxle to engine. Refer to MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING or AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING .
  3. Connect transfer to transaxle. Refer to TRANSFER DISMOUNTING AND REMOUNTING .
  4. Lift engine with transaxle and transfer (for 4WD model) into engine compartment, but do not remove lifting device.
  5. Install engine right mounting No. 1 bracket (8) to right mounting bracket (4), generator & P/S bracket and engine right mounting (3) with temporal tightening its bolts.
  6. Install engine left mounting bolts (9) with temporal tightening its nut.
  7. Install mounting member (1) to front member and suspension frame (7).
  8. Install suspension frame (7) with stabilizer bar and suspension control arms. Refer to FRONT SUSPENSION FRAME REMOVAL AND INSTALLATION for 4WD model.
  9. Tighten bolts and nuts of all parts installed in steps 5), 6) and 7) to specified torque.
    NOTE:
    • Be sure to tighten engine right mounting No.1 bracket bolt (10) previously, and tighten engine left mounting bolts (9).
    • Be sure to tighten mounting member to suspension frame bolts (12) or nuts (12) previously, and tighten mounting member to body bolts (11).

      Tightening torque 

      Engine mounting bolts and nut (a): 55 N.m (5.5 kg-m, 40.0 lb-ft)

      Engine front and rear mounting nut (b): 45 N.m (4.5 kg-m, 32.5 lb-ft)

  10. Remove lifting device.
  11. Reverse removal procedures for installation of reminder.
    • Push in each drive shaft joint fully so that snap ring engages with differential gear or center bearing support. Use care not to damage oil seal lip when inserting.
    • Clamp electric wire securely.
      Fig 1: Identifying Engine Assembly Mountings
      G00784846Courtesy of SUZUKI OF AMERICA CORP.
  12. For 4WD model, connect propeller shaft. Refer to Propeller Shaft Removal and Installation .
  13. Adjust gear shift control cable. Refer to Gear Shift Lever and Cable Removal and Installation .
  14. Install generator belt (Power steering pump drive belt). Refer to GENERATOR DRIVE BELT .
  15. Refill transaxle with A/T fluid or gear oil. Refer toDRAINING & REFILLING (A/T) or CHANGING FLUID (M/T).
  16. For 4WD model, refill transfer with transfer oil. Refer to TRANSFER OIL CHANGE .
  17. Refill engine with engine oil.
  18. Refill cooling system. Refer to COOLING SYSTEM FLUSH AND REFILL .
  19. Upon completion of installation, check to make sure that there is no fuel leakage, coolant leakage, transaxle oil leakage, transfer oil leakage or exhaust gas leakage at each connection.
  20. Adjust accelerator cable play. Refer to Accelerator Cable Adjustment .
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