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Engine Removal and Installation: Removal

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Remove the hood. Refer to HOOD REMOVAL AND INSTALLATION .
  4. Drain the engine oil.
  5. Disconnect the negative battery cable.
    Fig 1: Identifying Fuel Pump Fuse
    G04716438Courtesy of SUZUKI OF AMERICA CORP.
  6. Discharge the air conditioning (A/C) system, if equipped. Refer to DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM .
  7. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  8. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
  9. Disconnect the breather tubes from the camshaft cover.
  10. Remove the right front wheel. Refer to WHEEL REMOVAL AND INSTALLATION .
  11. Remove the right front wheel well splash shield.
  12. Remove the serpentine accessory drive belt. Refer to SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION .
    Fig 2: Identifying Camshaft Cover
    G04716395Courtesy of SUZUKI OF AMERICA CORP.
  13. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
  14. Remove the cooling system radiator and the engine cooling fans. Refer to RADIATOR REMOVAL AND INSTALLATION .
  15. Disconnect the upper radiator hose from the thermostat housing.
  16. Disconnect the power steering return hose from the power steering pump.
  17. Disconnect the power steering pressure hose from the power steering pump.
  18. Disconnect the electrical connector at the Direct Ignition System (DIS) coil and the Engine Control Module (ECM) ground terminal and at the starter motor.
    Fig 3: Identifying Upper Radiator Hose From Thermostat Housing
    G04716461Courtesy of SUZUKI OF AMERICA CORP.
  19. Disconnect the Oxygen (O2) sensor connector, if equipped.
  20. Disconnect the Electric Throttle Control (ETC) connector.
  21. Disconnect the engine Coolant Temperature Sensor (CTS) connector.
  22. Disconnect the generator voltage regulator connector and power lead.
    Fig 4: Identifying Coolant Hoses To Throttle Body
    G04716440Courtesy of SUZUKI OF AMERICA CORP.
  23. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  24. Disconnect the fuel return line at the fuel rail.
  25. Disconnect the fuel feed line at the fuel rail.
  26. Remove the fuel rail and injector channel cover as an assembly. Refer to FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION .
  27. Disconnect the coolant hose at the throttle body.
  28. Disconnect the heater outlet hose at the coolant pipe.
  29. Disconnect the coolant bypass hose from the cylinder head.
  30. Disconnect the surge tank coolant hose from the coolant pipe.
  31. Disconnect the lower radiator hose from the coolant pipe.
  32. Disconnect the starter solenoid "S" terminal wire and power lead.
  33. Remove the A/C compressor. Refer to COMPRESSOR REMOVAL AND INSTALLATION .
    Fig 5: Identifying Lower Radiator Hose From Coolant Pipe
    G04716463Courtesy of SUZUKI OF AMERICA CORP.
  34. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
  35. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe.
  36. Remove the exhaust flex pipe.
    Fig 6: Identifying Catalytic Converter To Connecting Pipe
    G04716464Courtesy of SUZUKI OF AMERICA CORP.
  37. Remove the crankshaft pulley bolts.
  38. Remove the crankshaft pulley.
  39. Disconnect the vacuum lines at the charcoal canister purge solenoid.
  40. Disconnect the electrical connector at the Charcoal Canister Purge (CCP) and the Exhaust Gas Recirculation (EGR) solenoid.
  41. Disconnect the electrical connector at the oil pressure switch.
  42. Disconnect the Crankshaft Position Sensor (CPS) connector.
  43. Disconnect the knock sensor connector.
    Fig 7: Identifying Crankshaft Pulley And Bolts
    G04716407Courtesy of SUZUKI OF AMERICA CORP.
  44. Remove the lower reaction rod bracket bolts.
  45. Remove the lower reaction rod bracket.
  46. Remove the lower reaction rod mount bolt.
  47. Remove the lower reaction rod mount.
    Fig 8: Identifying Lower Reaction Rod Mount
    G04716466Courtesy of SUZUKI OF AMERICA CORP.
  48. Remove the rubber cover as a service hole.
  49. Remove the transaxle torque converter bolts through the service hole, if automatic transaxle equipped.
  50. Remove the transaxle bell housing bolts and the oil pan flange bolts.
  51. Support the transaxle with a floor jack.
  52. Install the engine lifting device.
    Fig 9: Removing/Installing Transaxle Torque Converter Bolt Through Service Hole
    G04716467Courtesy of SUZUKI OF AMERICA CORP.
  53. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt.
  54. Remove the right engine mount bracket from the engine block and frame mount. Refer to Engine Mount Removal and Installation .
  55. Separate the engine block from the transaxle. Remove the engine.
    Fig 10: Identifying Engine Block From Transaxle
    G04716433Courtesy of SUZUKI OF AMERICA CORP.
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