Engine Assembly Removal

Tools Required 

1. DW110-060 Engine Assembly Lift Support
2. DW010-010 Power Pack Stand

1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant. Refer to MANUAL HVAC SYSTEM .
9. Remove the engine beautification cover.
10. Remove the air filter snorkel.
Fig 1: Removing Air Filter Snorkel
Courtesy of SUZUKI OF AMERICA CORP.
11. Remove the air filter housing assembly.
Fig 2: Removing Air Filter Housing Assembly
Courtesy of SUZUKI OF AMERICA CORP.
12. Remove the breather hose.
13. Disconnect the throttle cable from the throttle body assembly.
Fig 3: Disconnecting Throttle Cable From Throttle Body Assembly
Courtesy of SUZUKI OF AMERICA CORP.
14. Disconnect the coolant reservoir hoses.
15. Remove the coolant reservoir. Refer to SURGE TANK REMOVAL .
Fig 4: Removing Coolant Reservoir
Courtesy of SUZUKI OF AMERICA CORP.
16. Disconnect the power steering pump outlet pipe.
17. Disconnect the fuel rail hose and fuel feeding/return pipe.
Fig 5: Disconnecting Fuel Rail Hose & Fuel Feeding/Return Pipe
Courtesy of SUZUKI OF AMERICA CORP.
18. Disconnect the connectors on the O2S, EGR, charcoal canister purge solenoid valve, MAP sensor, Throttle body, engine oil pressure sensor, CMP sensor, knock sensor, VIS, and the engine coolant temperature sensor.
Fig 6: Disconnecting Connectors
Courtesy of SUZUKI OF AMERICA CORP.
19. Detach wiring harness from the wiring harness bracket on the cylinder block.
Fig 7: Detaching Wiring Harness From Wiring Harness Bracket On Cylinder Block
Courtesy of SUZUKI OF AMERICA CORP.
20. Disconnect the engine block ground by removing the engine block ground bolts.
Fig 8: Disconnecting Engine Block Ground
Courtesy of SUZUKI OF AMERICA CORP.
21. Remove the battery.
Fig 9: Removing Battery
Courtesy of SUZUKI OF AMERICA CORP.
22. Disconnect the automatic transaxle cable.
23. Disconnect the inhibit switch connector.
24. Disconnect the connectors on the transaxle. Refer to AXLE SHAFTS .
25. Disconnect the alternator connector and wiring harness. Refer to GENERATOR .
Fig 10: Disconnecting Alternator Connector & Wiring Harness
Courtesy of SUZUKI OF AMERICA CORP.
26. Remove the upper and lower radiator hoses. Refer to RADIATOR REMOVAL .
27. Remove the front wheels.
28. Remove the engine under covers.
Fig 11: Removing Engine Under Covers
Courtesy of SUZUKI OF AMERICA CORP.
29. Remove the front axle shaft. Refer to AXLE SHAFTS .
30. Remove the front muffler. Refer to MUFFLER -- FRONT REMOVAL .
Fig 12: Removing Front Muffler
Courtesy of SUZUKI OF AMERICA CORP.
31. Support the engine assembly using the engine assembly lift support DW110-060.
Fig 13: Supporting Engine Assembly Using Lift Support
Courtesy of SUZUKI OF AMERICA CORP.
32. Remove the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.
Fig 14: Removing Front Engine Mount Bracket-To-Damper Bush Bolt/Nut
Courtesy of SUZUKI OF AMERICA CORP.
33. Remove the center front suspension member bolts and the center front suspension member.
Fig 15: Removing Center Front Suspension Member Bolts
Courtesy of SUZUKI OF AMERICA CORP.
34. Disconnect the connector on the compressor.
35. Disconnect the refrigerant suction and discharge pipe block from the compressor.
Fig 16: Disconnecting Refrigerant Suction
Courtesy of SUZUKI OF AMERICA CORP.
36. Remove the oil filter.
Fig 17: Removing Oil Filter
Courtesy of SUZUKI OF AMERICA CORP.
37. Support the engine and transaxle with the power pack stand DW010-010.
Fig 18: Supporting Engine & Transaxle With Power Pack Stand
Courtesy of SUZUKI OF AMERICA CORP.
38. Remove the engine mount bracket (RH). Refer to Engine Mount (RH) Removal  .
Fig 19: Removing Engine Mount Bracket (RH)
Courtesy of SUZUKI OF AMERICA CORP.
39. Remove the engine mount bracket (LH). Refer to Engine Mount (LH) Removal 
40. Separate the engine and transaxle assembly from the engine compartment.
Fig 20: Separating Engine & Transaxle Assembly
Courtesy of SUZUKI OF AMERICA CORP.
41. Remove the starter. Refer to STARTER .
Fig 21: Removing Starter
Courtesy of SUZUKI OF AMERICA CORP.
42. Remove three (3) transaxle torque converter bolts.
Fig 22: Removing Transaxle Torque Converter Bolts
Courtesy of SUZUKI OF AMERICA CORP.
43. Remove the transaxle-to-engine block bolts.
Fig 23: Removing Transaxle-To-Engine Block Bolts
Courtesy of SUZUKI OF AMERICA CORP.
44. Remove the rear transaxle mount bracket.
45. Remove the front damper bush bracket.
Fig 24: Removing Front Damper Bush Bracket
Courtesy of SUZUKI OF AMERICA CORP.
46. Remove the engine block-to-transaxle bolts.
Fig 25: Removing Engine Block-To-Transaxle Bolts
Courtesy of SUZUKI OF AMERICA CORP.
47. Remove the engine block-to-transaxle bolts.
48. Remove the engine assembly from the transaxle.
    CAUTION: Be careful not to damage the torque converter when removing the transaxle.

Fig 26: Removing Engine Assembly From Transaxle

Courtesy of SUZUKI OF AMERICA CORP.