Engine Assembly Removal

Tools Required: 

DW110-060 Engine Assembly Lift Support 

DW010-010 Power Pack Stand 

1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant. Refer to DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM .
9. Remove the engine beautification cover.
10. Remove the air filter snorkel.
    Fig 1: Identifying Air Filter Snorkel

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove the air filter housing assembly.
    Fig 2: Removing/Installing Air Filter Housing Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
12. Remove the breather hose.
13. Disconnect the coolant reservoir hoses.
14. Remove the coolant reservoir. Refer to SURGE TANK REMOVAL .
    Fig 3: Removing/Installing Coolant Reservoir Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
15. Disconnect the power steering pump outlet pipe.
16. Disconnect the fuel rail hose and fuel feeding/return pipe.
    Fig 4: Identifying Fuel Rail Hose And Fuel Feeding/Return Pipe

    Courtesy of SUZUKI OF AMERICA CORP.
17. Disconnect the connectors on the O2S, EGR, charcoal canister purge solenoid valve, MAP sensor, Throttle body, engine oil pressure sensor, CMP sensor, knock sensor, VIS and the engine coolant temperature sensor.
    Fig 5: Disconnecting Engine Coolant Temperature Connector

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18. Detach wiring harness from the wiring harness bracket on the cylinder block.
    Fig 6: Identifying Wiring Harness Bracket

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19. Disconnect the engine block ground by removing the engine block ground bolts.
    Fig 7: Removing/Installing Engine Block Ground Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
20. Remove the battery.
    Fig 8: Removing/installing Battery Hold-Down Bar Clamp And Retaining Nuts

    Courtesy of SUZUKI OF AMERICA CORP.
21. Disconnect the automatic transaxle cable.
22. Disconnect the inhibit switch connector.
23. Disconnect the connectors on the transaxle. Refer to TRANSAXLE ASSEMBLY REMOVAL .
24. Disconnect the generator connector and wiring harness. Refer to GENERATOR REMOVAL .
    Fig 9: Identifying Generator Connector And Wiring Harness

    Courtesy of SUZUKI OF AMERICA CORP.
25. Remove the upper and lower radiator hoses. Refer to RADIATOR REMOVAL .
26. Remove the front wheels.
27. Remove the engine under covers.
    Fig 10: Removing/Installing Engine Under Cover Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
28. Remove the front axle shaft. Refer to DRIVE AXLE ASSEMBLY REMOVAL .
29. Remove the front muffler. Refer to MUFFLER - FRONT REMOVAL .
    Fig 11: Identifying Exhaust Manifold Retaining Bolts And Nuts

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30. Support the engine assembly using the engine assembly lift support DW110-060.
    Fig 12: Identifying Engine Assembly Lift Support DW110-060

    Courtesy of SUZUKI OF AMERICA CORP.
31. Remove the impact beam. Refer to IMPACT BEAM REMOVAL .
    Fig 13: Identifying Impact Beam

    Courtesy of SUZUKI OF AMERICA CORP.
32. Remove the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.
    Fig 14: Identifying Front And Rear Engine Mount Bracket-To-Damper Bush Bolt/Nut

    Courtesy of SUZUKI OF AMERICA CORP.
33. Remove the center front suspension member bolts and the center front suspension member.
    Fig 15: Removing/Installing Center Front Suspension Member Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
34. Disconnect the connector on the compressor.
35. Disconnect the refrigerant suction and discharge pipe block from the compressor.
    Fig 16: Removing/Installing Compressor Discharge Hose Retaining Nut

    Courtesy of SUZUKI OF AMERICA CORP.
36. Remove the oil filter.
    Fig 17: Removing Oil Filter

    Courtesy of SUZUKI OF AMERICA CORP.
37. Support the engine and transaxle with the power pack stand DW010-010.
    Fig 18: Supporting Engine And Transaxle Assembly With Power Pack Stand (DW010-010)

    Courtesy of SUZUKI OF AMERICA CORP.
38. Remove the engine mount bracket (RH). Refer to Engine Mount (RH) Removal .
    Fig 19: Removing/Installing Engine Mount Bracket (RH) Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
39. Remove the engine mount bracket (LH). Refer to Engine Mount (LH) Removal .
40. Separate the engine and transaxle assembly from the engine compartment.
    Fig 20: Identifying Engine Mount Bracket (LH)

    Courtesy of SUZUKI OF AMERICA CORP.
41. Remove the starter. Refer to STARTER REMOVAL .
    Fig 21: Removing/Installing Starter Mounting Bolts

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42. Remove three (3) transaxle torque converter bolts.
    Fig 22: Removing/Installing Transaxle Torque Converter Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
43. Remove the transaxle-to-engine block bolts.
    Fig 23: Removing/Installing Transaxle-To-Engine Block Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
44. Remove the rear transaxle mount bracket.
45. Remove the front damper bush bracket.
    Fig 24: Removing/Installing Front Damper Bush Bracket Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
46. Remove the engine block-to-transaxle bolts.
    Fig 25: Removing/Installing Engine Block-To-Transaxle Bolts

    Courtesy of SUZUKI OF AMERICA CORP.
47. Remove the engine block-to-transaxle bolts.
48. Remove the engine assembly from the transaxle.
    CAUTION: Be careful not to damage the torque converter when removing the transaxle.
    Fig 26: Removing/Installing Engine Assembly Retaining Bolts

    Courtesy of SUZUKI OF AMERICA CORP.