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Engine Assembly Removal and Installation: Removal

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCEDURE .
  2. Disconnect negative (-) cable at battery.
  3. Remove engine hood.
  4. Drain engine oil.
  5. Drain coolant referring to COOLANT DRAINING .
  6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION.
  7. Disconnect accelerator cable (1) from throttle body.
    Fig 1: Identifying Accelerator Cable
    G04721374Courtesy of SUZUKI OF AMERICA CORP.
  8. Detach fuse/relay box, then remove strut tower bar and surge tank cover.
  9. Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.
  10. Remove intake control valve, referring to THROTTLE BODY REMOVAL AND INSTALLATION .
  11. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
  12. Remove ignition coil covers.
  13. Disconnect the following electric lead wires:
    • Injector wire coupler
    • CMP sensor coupler
    • Ignition coil couplers
    • CKP sensor coupler
    • MAP sensor coupler
    • TP sensor (1) coupler
    • IAC valve (2) coupler
    • Earth wire (3) from surge tank
    • EVAP canister purge valve (5) coupler
    • EGR valve (6) coupler
    • Oxygen sensor-1 and -2 couplers (Refer to EXHAUST MANIFOLD REMOVAL AND INSTALLATION. )
    • Coolant temperature sensor coupler
    • Knock sensor coupler
    • Generator wires
    • Starter wires
    • Oil pressure wire
    • P/S pump wire
    • Earth wire from generator bracket
    • Engine block heater (if equipped)
  14. Remove clamps and brackets (4).
  15. Disconnect the following hoses:
    • Heater hose (7) from heater water pipe and water outlet cap
    • Tank pressure control solenoid valve hose from intake manifold
    • EVAP canister hose from canister purge pipe
    • Brake booster vacuum hose
  16. Remove EVAP canister purge valve (5).
    Fig 2: Identifying TP Sensor, IAC Valve, Wire, EVAP Canister Purge Valve, EGR Valve, Brackets And Heater Hose
    G04721375Courtesy of SUZUKI OF AMERICA CORP.
  17. Disconnect the following hoses at the location shown in figure:
    • Fuel feed hose (1) from fuel feed pipe
    • Fuel return hose (2) from fuel return pipe
      Fig 3: Identifying Fuel Feed Hose And Return Hose
      G04721376Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove P/S pump assembly referring to P/S PUMP REMOVAL AND INSTALLATION.
  19. Remove A/C compressor assembly referring to COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION : Manual Type, Compressor Assembly Removal and Installation: Automatic Type.
  20. Remove steering shaft lower assembly referring to STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  21. Raise vehicle.
  22. Remove front differential housing with differential from chassis if equipped. Refer to FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING : Front.
  23. Remove exhaust No.1 pipe referring to EXHAUST MANIFOLD REMOVAL AND INSTALLATION.
  24. Remove exhaust manifold stiffener from transmission.
  25. Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)
    Fig 4: Identifying A/T Fluid Hose Clamps And Engine Mounting Bracket
    G04721377Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove clutch housing lower plate.
  27. Remove torque converter bolts (for A/T vehicle).
  28. Remove starter motor.
  29. Lower vehicle.
  30. Support transmission.
    CAUTION: Do not support A/T by placing a jacking equipment under oil pan. If may damage to A/T.
  31. Remove bolts and nuts fastening cylinder block and transmission.
    Fig 5: Identifying Transmission Case Bolts And Nuts
    G04721378Courtesy of SUZUKI OF AMERICA CORP.
  32. Install lifting device.
  33. Disconnect engine side mounting brackets (1) from engine mountings (2) by removing nuts (3).
    Fig 6: Identifying Engine Side Mounting Brackets, Engine Mountings & Nuts
    G04721379Courtesy of SUZUKI OF AMERICA CORP.
  34. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
  35. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.
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