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Engine Assembly Installation

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Installation should follow the removal procedure in the reverse order.
  2. Tighten the engine block-to-transaxle bolts near the rear transaxle bracket.

    Tighten: 

    Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).

    Fig 1: Identifying Engine Assembly
    G04718919Courtesy of SUZUKI OF AMERICA CORP.
  3. Tighten the engine block-to-transaxle bolts near the front engine mount bracket.

    Tighten: 

    Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).

    Fig 2: Identifying Engine Block-To-Transaxle Bolts
    G04718920Courtesy of SUZUKI OF AMERICA CORP.
  4. Tighten the transaxle-to-engine block bolts near the rear support bracket.

    Tighten: 

    Tighten the transaxle-to-engine block bolts to 60 - 85 N.m (44 - 63 lb-ft).

    Fig 3: Identifying Transaxle-To-Engine Block Bolts
    G04718921Courtesy of SUZUKI OF AMERICA CORP.
  5. Tighten the 3 flexible plate-to-torque converter retaining bolts.

    Tighten: 

    Tighten the transaxle torque converter bolts to 40 - 50 N.m (30 - 37 lb-ft).

    Fig 4: Identifying Transaxle Torque Converter Retaining Bolts
    G04718922Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the rear transaxle mount bracket.

    Tighten: 

    Tighten the rear transaxle mount bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).

    Fig 5: Identifying Rear Transaxle Mount Bracket And Bolts
    G04718923Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the front damper bush bracket.

    Tighten: 

    Tighten the front damper bush bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).

    Fig 6: Identifying Front Damper Bush Bracket And Retaining Bolts
    G04718924Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the starter. Refer to STARTER INSTALLATION .
  9. Install the engine and transaxle assembly using the power pack stand DW010-010.
    Fig 7: Identifying Engine And Transaxle Assembly On Power Pack Stand DW010-010
    G04718910Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the engine mount bracket (LH). Refer to Engine Mount (LH) Installation .
    Fig 8: Identifying Engine Mount Bracket (LH) And Retaining Bolts
    G04718892Courtesy of SUZUKI OF AMERICA CORP.
  11. Install the engine mount bracket (RH). Refer to Engine Mount (RH) Installation .
    Fig 9: Identifying Engine Mount Bracket (RH) And Retaining Nuts/Bolts
    G04718890Courtesy of SUZUKI OF AMERICA CORP.
  12. Support the engine and transaxle assembly using the engine assembly lift support DW110-060.
  13. Remove the power pack stand DW010-010.
    Fig 10: Identifying Engine And Transaxle Assembly With Power Pack Stand (DW010-010)
    G04718928Courtesy of SUZUKI OF AMERICA CORP.
  14. Install the oil filter.

    Tighten: 

    Tighten the oil filter to 12 - 16 N.m (106 - 142 lb-in.).

    Fig 11: Identifying Oil Filter
    G04718929Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the center front suspension member.

    Tighten: 

    Tighten the center front suspension member bolts to 80 - 100 N.m (59 - 74 lb-ft).

    Fig 12: Identifying Center Front Suspension Member Bolts
    G04718930Courtesy of SUZUKI OF AMERICA CORP.
  16. Tighten the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.

    Tighten: 

    • Tighten the front engine mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft).
    • Tighten the rear transaxle mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft).
      Fig 13: Identifying Front And Rear Engine Mount Bracket-To-Damper Bush Bolt/Nut
      G04718931Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the front muffler. Refer to MUFFLER - FRONT INSTALLATION .
    Fig 14: Identifying Exhaust Manifold Retaining Bolts And Nuts
    G04718932Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the impact beam. Refer to "IMPACT BEAM INSTALLATION ".
    Fig 15: Identifying Impact Beam
    G04718933Courtesy of SUZUKI OF AMERICA CORP.
  19. Install the axle shaft. Refer to DRIVE AXLE ASSEMBLY INSTALLATION .
  20. Install the engine under cover.

    Tighten: 

    Tighten the engine under cover bolts to 17 - 27 N.m (13 - 20 lb-ft).

    Fig 16: Identifying Engine Under Cover And Axle Shaft
    G04718934Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the battery.

    Tighten: 

    Tighten the battery retaining nuts to 4 N.m (35 lb-in.).

    Fig 17: Removing/installing Battery Hold-Down Bar Clamp And Retaining Nuts
    G04718900Courtesy of SUZUKI OF AMERICA CORP.
  22. Connect the connectors and cables on the transaxle. Refer to TRANSAXLE ASSEMBLY INSTALLATION .
  23. Connect the wiring harness, hoses, pipes, and connectors to the engine assembly.
  24. Install the coolant reservoir. Refer to SURGE TANK INSTALLATION .

    Tighten: 

    Tighten the coolant reservoir bolts to 3.5 - 4.5 N.m (31 - 40 lb-in.).

    Fig 18: Identifying Coolant Reservoir Retaining Bolts
    G04718887Courtesy of SUZUKI OF AMERICA CORP.
  25. Install the air filter housing.

    Tighten: 

    Tighten the air filter housing bolt to 8 - 12 N.m (71 - 106 lb-in.).

    Fig 19: Identifying Air Filter Housing Retaining Bolts
    G04718885Courtesy of SUZUKI OF AMERICA CORP.
  26. Install the air filter snorkel.

    Tighten: 

    Tighten the air filter snorkel retaining bolt to 5 - 7 N.m (44 - 62 lb-in.).

    Fig 20: Identifying Air Filter Snorkel Retaining Bolt
    G04718875Courtesy of SUZUKI OF AMERICA CORP.
  27. Install the engine beautification cover.

    Tighten: 

    Tighten the engine beautification cover bolts to 8 - 12 N.m (71 - 106 lb-in.).

  28. Connect the connectors and hoses.
  29. Recharge the refrigerant. Refer to DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM .
  30. Fill the power steering oil.
  31. Fill the transaxle oil.
  32. Fill the engine oil.
    Fig 21: Identifying Engine Beautification Cover Retaining Bolts
    G04718876Courtesy of SUZUKI OF AMERICA CORP.
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