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Engine Removal and Installation: Installation

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the engine into the engine compartment.
  2. Align the engine alignment pins to the transaxle.
  3. Install the transaxle bell housing bolts.

    Tighten 

    Tighten the transaxle bell housing bolts to 75 N.m (55 lb-ft).

  4. Install the oil pan flange-to-transaxle bolts.

    Tighten 

    Tighten the oil pan flange-to-transaxle bolts to 40 N.m (30 lb-ft).

    Fig 1: Installing Oil Pan Flange-To-Transaxle Bolts
    G04102749Courtesy of SUZUKI OF AMERICA CORP.
  5. Install the right engine mount to the engine block mount and the frame mount.
  6. Install the right engine mount bracket retaining bolts and nuts.

    Tighten 

    Tighten the engine mount bracket retaining bolts and nuts to 55 N.m (41 lb-ft).

    Fig 2: Installing Right Engine Mount Bracket Retaining Bolts
    G04102750Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the floor jack used for support of the transmission.
  8. Remove the engine lifting device.
  9. Install the transaxle torque converter bolts, if automatic transaxle equipped.

    Tighten 

    Tighten the transaxle torque converter bolts to 60 N.m (44 lb-ft).

  10. Install the rubber cover as a service hole.
    Fig 3: Installing Rubber
    G04102751Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the lower reaction rod mount.
  12. Install the lower reaction rod mount bolt.

    Tighten 

    Tighten the lower reaction rod mount bolt to 55 N.m (41 lb-ft).

  13. Install the lower reaction rod bracket.
  14. Install the lower reaction rod bracket bolts.

    Tighten 

    Tighten the lower reaction rod bracket bolt to 69 N.m (49 lb-ft).

    Fig 4: Installing Lower Reaction Rod Mount Bolt
    G04102752Courtesy of SUZUKI OF AMERICA CORP.
  15. Connect the vacuum lines at the CCP solenoid.
  16. Connect the electrical connector to the CCP and the EGR solenoid.
  17. Connect the oil pressure switch connector.
  18. Install the crankshaft pulley.
  19. Install the crankshaft pulley bolts.

    Tighten 

    Tighten the crankshaft pulley bolts to 20 N.m (15 lb-ft) using a torque wrench.

    Fig 5: Installing Crankshaft Pulley
    G04102753Courtesy of SUZUKI OF AMERICA CORP.
  20. Connect the CPS connector.
  21. Install the exhaust flex pipe.
  22. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.

    Tighten 

    Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N.m (26 lb-ft).

    Fig 6: Installing Exhaust Flex Pipe
    G04102754Courtesy of SUZUKI OF AMERICA CORP.
  23. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.

    Tighten 

    Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N.m (26 lb-ft).

  24. Connect the power steering pressure hose.
  25. Connect the power steering return hose.
  26. Install the A/C compressor, if equipped. Refer to "COMPRESSOR REMOVAL AND INSTALLATION :".
  27. Install the serpentine accessory drive belt. Refer to "SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION :".
  28. Install the right front wheel well splash shield.
  29. Install the right front wheel. Refer to "WHEEL REMOVAL AND INSTALLATION :".
  30. Connect the fuel feed line to the fuel rail.
  31. Connect the fuel return line to fuel rail.
  32. Install the fuel rail and injector channel cover as an assembly. Refer to "FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION :".
  33. Connect all of the necessary vacuum lines including the brake booster vacuum hose.
  34. Connect the O2 sensor connector, if equipped.
  35. Connect the starter solenoid "S" terminal wire and power lead.
  36. Connect the generator voltage regulator connector.
  37. Connect the CTS connector.
  38. Connect the engine CTS connector.
  39. Connect the TPS connector.
  40. Connect the IAC valve connector.
  41. Connect the MAP sensor connector.
  42. Connect the knock sensor, if necessary.
    Fig 7: Connecting TPS Connector
    G04102757Courtesy of SUZUKI OF AMERICA CORP.
  43. Connect the electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor.
  44. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
  45. Connect the breather tubes to the camshaft cover.
  46. Connect the MAT sensor connector.
  47. Install the cooling system radiator and the engine cooling fans. Refer to "RADIATOR REMOVAL AND INSTALLATION :".
    Fig 8: Connecting Breather Tubes To Camshaft Cover
    G04102758Courtesy of SUZUKI OF AMERICA CORP.
  48. Connect the lower radiator hose to the coolant pipe.
  49. Connect the upper radiator hose to the thermostat housing.
  50. Connect the heater inlet hose to the cylinder head.
  51. Connect the heater outlet hose to the coolant pipe.
  52. Connect the coolant surge tank hose to the coolant pipe.
  53. Connect the coolant hose to the throttle body.
    Fig 9: Connecting Hoses
    G04102759Courtesy of SUZUKI OF AMERICA CORP.
  54. Connect the throttle cable to the throttle body and the intake manifold bracket.
  55. Install the fuel pump fuse.
  56. Connect the negative battery cable.
  57. Refill the engine crankcase with engine oil.
  58. Refill the engine coolant system. Refer to "DRAINING AND REFILLING THE COOLING SYSTEM :".
  59. Bleed the power steering system. Refer to "BLEEDING THE POWER STEERING SYSTEM :".
  60. Refill the A/C refrigerant system, if equipped. Refer to "DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM :".
  61. Install the hood. Refer to "HOOD REMOVAL AND INSTALLATION :".
    Fig 10: Connecting Throttle Cable To Throttle Body
    G04102760Courtesy of SUZUKI OF AMERICA CORP.
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