Engine Assembly Removal and Installation: Installation

WARNING: This page is about a different car, the 2007 Suzuki SX4. However, it is still accessible from the selected car via links, so may be relevant.

Install clutch cover and clutch disk, referring to INSTALLATION , if necessary (M/T model).
Connect transaxle to engine, referring to MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING or AUTOMATIC TRANSAXLE UNIT DISMOUNTING AND REMOUNTING , if removed.
Connect transfer to suspension frame, referring to TRANSFER DISMOUNTING AND REMOUNTING , if removed (4WD model).
Connect steering gear case to suspension frame, referring to STEERING GEAR CASE ASSEMBLY COMPONENTS , if removed.
Lift engine with transaxle, front suspension frame, front lower cross member, transfer (4WD model) and steering gear case into engine compartment with jack.
CAUTION: Before lifting engine, in order to avoid damage to A/C compressor, make clearance by rising it.
Tighten suspension frame mounting bolts and front lower cross member bolts, and then tighten bolts to specified torque.
Tightening torque

Suspension frame mounting bolt a: 150 N.m (15.0 kg-m, 108.5 lb-ft)

Front lower cross member bolt b: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Fig 1: Identifying Suspension Frame Mounting & Front Lower Cross Member Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install engine right mounting, engine right mounting No.1 bracket and engine left mounting bracket, and then tighten bolts and nuts to specified torque referring to ENGINE MOUNTINGS COMPONENTS .
Remove jack.
Connect steering lower shaft to pinion shaft, referring to INSTALLATION .
Connect propeller shaft, referring to INSTALLATION (4WD model).
Install exhaust center pipe, referring to EXHAUST SYSTEM COMPONENTS .
Connect right and left drive shaft joints to differential gear, referring to INSTALLATION .
Reverse disconnected hoses, cables and electric wires for connection noting the following.
Tighten bolts and nuts to specified torque.

Tightening torque

Starting motor terminal nut a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Generator terminal nut b: 5 N.m (0.5 kg-m, 4.0 lb-ft)

Battery ground bolt c: 25 N.m (2.5 kg-m, 18.0 lb-ft)

Ground terminal bolt d: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Fig 2: Identifying Hoses, Cables & Electric Wires Connection
Courtesy of SUZUKI OF AMERICA CORP.
Connect P/S fluid reservoir hose (1) and then install P/S fluid reservoir (2) to bracket.

Fig 3: Identifying P/S Fluid Reservoir Hose
Courtesy of SUZUKI OF AMERICA CORP.
Refill P/S fluid, referring to P/S FLUID CHANGE .
Install condenser cooling fan to radiator, referring to INSTALLATION .
Install A/C compressor to its bracket (if removed), referring to INSTALLATION .
Install air cleaner assembly, referring to INSTALLATION .
Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
Refill coolant, referring to COOLING SYSTEM FLUSH AND REFILL .
Refill transfer oil, referring to TRANSFER OIL CHANGE (4WD model).
Refill transaxle oil, referring to MANUAL TRANSAXLE OIL CHANGE or A/T FLUID CHANGE .
Refill engine oil, referring to ENGINE OIL AND FILTER CHANGE .
Install water pump and generator drive belt, referring to INSTALLATION .
Install right and left side engine under covers.
Install battery and battery tray with ECM.
Connect ECM connectors.
Connect negative and positive cable at battery.
Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.