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Engine Assembly Installation

WARNING: This page is about a different car, the 2004 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Installation should follow the removal procedure in the reverse order.
  2. Tighten the engine block-to-transaxle bolts near the rear transaxle bracket.

    Tighten 

    1. Tighten the engine block-to-transaxle bolts to 60-85 N.m (44-63 lb-ft).
    3. Fig 1: Tightening Engine Block-To-Transaxle
    G01985642Courtesy of SUZUKI OF AMERICA CORP.
  3. Tighten the engine block-to-transaxle bolts near the front engine mount bracket.

    Tighten 

    1. Tighten the engine block-to-transaxle bolts to 60-85 N.m (44-63 lb-ft).
    4. Fig 2: Tightening Engine Block-To-Transaxle Bolts
    G01985643Courtesy of SUZUKI OF AMERICA CORP.
  4. Tighten the transaxle-to-engine block bolts near the rear support bracket.

    Tighten 

    1. Tighten the transaxle-to-engine block bolts to 60-85 N.m (44-63 lb-ft).
    5. Fig 3: Tightening Transaxle-To-Engine Block Bolts
    G01985644Courtesy of SUZUKI OF AMERICA CORP.
  5. Tighten the three (3) flexible plate-to-torque converter retaining bolts.

    Tighten 

    1. Tighten the transaxle torque converter bolts to 40-50 N.m (30-37 lb-ft).
    6. Fig 4: Tightening Flexible Plate-To-Torque Converter Retaining Bolts
    G01985645Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the rear transaxle mount bracket.

    Tighten 

    1. Tighten the rear transaxle mount bracket bolts to 55-75 N.m (26-55 lb-ft).
    7. Fig 5: Installing Rear Transaxle Mount Bracket
    G01985646Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the front damper bush bracket.

    Tighten 

    1. Tighten the front damper bush bracket bolts to 55-75 N.m (26-55 lb-ft).
    8. Fig 6: Installing Front Damper Bush Bracket
    G01985647Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the starter. Refer to STARTER .
  9. Install the engine and transaxle assembly using the power pack stand DW010-010.
    10. Fig 7: Installing Engine & Transaxle Assembly
    G01985648Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the engine mount bracket (LH). Refer to Engine Mount (LH) Removal  .
    11. Fig 8: Installing Engine Mount Bracket (LH)
    G01985649Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the engine mount bracket (RH). Refer to Engine Mount (RH) Installation  .
    12. Fig 9: Installing Engine Mount Bracket (RH)
    G01985650Courtesy of SUZUKI OF AMERICA CORP.
  12. Support the engine and transaxle assembly using the engine assembly lift support DW110-060.
  13. Remove the power pack stand DW010-010.
    14. Fig 10: Removing Power Pack Stand
    G01985651Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the oil filter.

    Tighten 

    1. Tighten the oil filter to 12-16 N.m (9-12 lb-in).
    15. Fig 11: Installing Oil Filter
    G01985652Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the center front suspension member.

    Tighten 

    1. Tighten the center front suspension member bolts to 80-100 N.m (59-74 lb-ft).
    16. Fig 12: Installing Center Front Suspension Member
    G01985653Courtesy of SUZUKI OF AMERICA CORP.
  16. Tighten the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.

    Tighten 

    1. Tighten the front engine mount bracket-to-damper bush bolt/nut to 70-90 N.m (52-66 lb-ft).
    2. Tighten the rear transaxle mount bracket-to-damper bush bolt/nut to 70-90 N.m (52-66 lb-ft).
    17. Fig 13: Tightening Front Engine Mount Bracket-To-Damper
    G01985654Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the front muffler. Refer to MUFFLER -- FRONT INSTALLATION .
    18. Fig 14: Installing Front Muffler
    G01985655Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the axle shaft. Refer to AXLE SHAFTS .
  19. Install the engine under cover.

    Tighten 

    1. Tighten the engine under cover bolts to 17-27 N.m (13-20 lb-ft).
    20. Fig 15: Installing Engine Under Cover
    G01985656Courtesy of SUZUKI OF AMERICA CORP.
  20. Connect the connectors and cables on the transaxle. Refer to AXLE SHAFTS .
  21. Connect the wiring harness, hoses, pipes, and connectors to the engine assembly.
  22. Install the coolant reservoir. Refer to SURGE TANK INSTALLATION .

    Tighten 

    1. Tighten the coolant reservoir bolts to 3.5-4.5 N.m (31-40 lb-in).
    23. Fig 16: Installing Coolant Reservoir
    G01985657Courtesy of SUZUKI OF AMERICA CORP.
  23. Install the air filter housing.

    Tighten 

    1. Tighten the air filter housing bolt to 8-12 N.m (71-106 lb-in).
    24. Fig 17: Installing Air Filter Housing
    G01985658Courtesy of SUZUKI OF AMERICA CORP.
  24. Install the air filter snorkel.

    Tighten 

    1. Tighten the air filter snorkel retaining bolt to 5-7 N.m (44-62 lb-in).
    25. Fig 18: Installing Air Filter Snorkel
    G01985659Courtesy of SUZUKI OF AMERICA CORP.
  25. Install the engine beautification cover.

    Tighten 

    1. Tighten the engine beautification cover bolts to 8-12 N.m (71-106 lb-in).
  26. Connect the connectors and hoses.
  27. Recharge the refrigerant. Refer to MANUAL HVAC SYSTEM .
  28. Fill the power steering oil.
  29. Fill the transaxle oil.
  30. Fill the engine oil.
Fig 19: Filling Engine Oil
G01985660Courtesy of SUZUKI OF AMERICA CORP.
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