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Home >> Suzuki >> 2006 >> Aerio Base, AWD >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Engine Mechanical >> Repair Instructions >> Engine Assembly Removal and Installation >> Removal
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Engine Assembly Removal and Installation: Removal

  1. Release fuel pressure in fuel feed line by referring to FUEL PRESSURE RELIEF PROCEDURE .
  2. Disconnect negative cable at battery.
  3. Remove engine hood after disconnecting windshield washer hose.
  4. Drain cooling system.
    WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.
    Fig 1: Removing Radiator Drain Plug
    G04589715Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove radiator referring to RADIATOR REMOVAL AND INSTALLATION .
  6. Remove engine cover referring to ENGINE COVER REMOVAL AND INSTALLATION .
  7. Remove air cleaner outlet hose referring to AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION .
  8. Disconnect MAF sensor coupler (1).
  9. Remove air cleaner case assembly (2).
    Fig 2: Disconnecting MAF Sensor Coupler
    G04589716Courtesy of SUZUKI OF AMERICA CORP.
  10. Disconnect the following cables.
    • Accelerator cable (1) from throttle valve lever (2).
    • Shift and select cable from transaxle (for M/T model)
    • Gear select cable from transaxle (for A/T model)
      Fig 3: Disconnecting Accelerator Cable From Throttle Valve Lever
      G04589717Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove accelerator cable with its bracket from intake manifold.
  12. Disconnect the following hoses: See HOSES . See Fig 4
    HOSES

    Brake booster hose (1) from intake manifold Heater outlet hose (5) from heater outlet pipe
    Fuel feed hose (2) from delivery pipe Vacuum hose (6) from EVAP canister purge valve
    Fuel return hose (3) from return pipe P/S suction hose (7) and high pressure pipe (8) from P/S pump
    Heater inlet hose (4) from water outlet cap  
    Fig 4: Identifying Hoses
    G04589718Courtesy of SUZUKI OF AMERICA CORP.
  13. Disconnect the following connectors and wires: See CONNECTOR & WIRE IDENTIFICATION  table. See Fig 5.
    CONNECTOR & WIRE IDENTIFICATION

    Injector wire (1) Cylinder block heater connector (15) (if equipped)
    CMP sensor coupler (2) Heated oxygen sensor wire (16)
    Ignition coil wire (3) Starter wires (17)
    TP sensor coupler (4) Generator wires (18)
    IAC valve coupler (5) A/C magnetic switch wire (19) (if equipped)
    IAC valve coupler (6) Power steering pressure switch coupler (20)
    MAP sensor coupler (6) Vehicle speed sensor (21)
    CKP sensor coupler (7) Battery negative cable from transmission (22)
    Ground terminals from cylinder head (8) and throttle body (9) Input shaft speed sensor (23) (A/T)
    EVAP canister purge valve coupler (10) Output shaft speed sensor (24) (A/T)
    EGR valve coupler (11) Transmission range switch (25) (for A/T model)
    ECT sensor coupler (12) Valve body and transmission fluid temperature sensor connector (26) (for A/T model)
    Knock sensor coupler (13) Back-up light switch (for M/T model)
    Oil pressure switch wire (14)  
  14. Release the wire harness from clamps.
    Fig 5: Connector & Wire Identification
    G04589719Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove clutch operating cylinder (1) from transmission with hose still attached (for M/T model).
    NOTE: Suspend removed clutch operating cylinder at a place free from any possible damage during removal and installation of engine assembly.
    Fig 6: Removing Clutch Operating Cylinder From Transmission With Hose Attached
    G04589720Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove right and left engine under covers.
  17. Remove generator belt (Power steering pump drive belt) for equipped with A/C referring to GENERATOR DRIVE BELT REMOVAL AND INSTALLATION .
  18. Remove exhaust No.1 pipe and No. 2 pipe referring to EXHAUST PIPE REMOVAL AND INSTALLATION .
  19. Drain engine oil, transaxle oil for M/T vehicle or A/T fluid for A/T vehicle and transfer oil for 4WD vehicle.
  20. Remove drive shafts referring to FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  21. Separate propeller shaft front end from transfer output flange for 4WD vehicle.
  22. Remove A/C compressor from compressor bracket with hoses still attached, if equipped with A/C.
    NOTE: Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly.
  23. Remove intake manifold rear stiffener.
  24. Install lifting device.
  25. Remove mounting member (1) from front member and suspension frame (7).
  26. Remove suspension frame (7) with stabilizer bar and suspension control arms referring to FRONT SUSPENSION FRAME REMOVAL AND INSTALLATION for 4WD vehicle.
  27. Remove engine left mounting bolts (9).
  28. Remove engine right mounting No. 1 bracket (8).
    Fig 7: Removing Front Suspension Frame For 4WD Vehicle
    G04589721Courtesy of SUZUKI OF AMERICA CORP.
  29. Before removing engine with transaxle and transfer (for 4WD model) from vehicle body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transaxle.
  30. Lower engine with transaxle and transfer (for 4WD model) from vehicle body.
    NOTE: Before lowering engine, to avoid damage to A/C compressor, raise it through clearance made on engine crankshaft pulley side. At this time, use care so that no excessive force is applied to hoses.
    Fig 8: Lowering Engine
    G04589722Courtesy of SUZUKI OF AMERICA CORP.
  31. Disconnect transfer from transaxle referring to TRANSFER DISMOUNTING AND REMOUNTING for 4WD model.
  32. Disconnect transaxle from engine referring to MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING or AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING .
  33. Remove clutch cover and clutch disk referring to CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION (for M/T model).
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