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Home >> Suzuki >> 2007 >> Swift + >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 1.6L >> Repair Instructions >> Engine Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Crossmember, Nuts, And Bolts
    GM1371917Courtesy of GENERAL MOTORS CORP.
  1. Install the engine and transaxle assembly into the engine compartment.
  2. Install the right engine mount bracket to the engine block.
    3. NOTE: Refer to Fastener Notice .
  3. Install the mounting bolts to the bracket.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  4. Install the bracket to the engine mount with 2 retaining bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    5. Fig 2: View Of Upper Transaxle Mounting Bracket Bolts
    GM1245844Courtesy of GENERAL MOTORS CORP.
  5. Install the upper transaxle mounting bracket with 3 bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    6. Fig 3: View Of Torque Converter Bolts
    GM1245846Courtesy of GENERAL MOTORS CORP.
  6. Install the service cover to the transaxle torque converter with bolts.

    Tighten:  Tighten the bolts to 65 N.m (48 lb ft).

  7. Install the rubber to the oil pan.
  8. Position the starter electrical wire on the solenoid terminal.
  9. Install the starter solenoid nuts.

    Tighten:  Tighten the nuts to 15 N.m (11 lb ft).

  10. Install the lower mounting bolts to the starter.

    Tighten:  Tighten the bolt to 43 N.m (32 lb ft).

  11. Connect the ECT sensor connector.
    12. Fig 4: View Of Intake Manifold Support Bracket
    GM1371868Courtesy of GENERAL MOTORS CORP.
  12. Install the intake manifold support bracket.
    1. Install the upper bracket bolts to the intake manifold.

      Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    2. Install the lower bracket bolts to the engine block.

      Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    13. Fig 5: Identifying Canister Purge Solenoid Valve
    GM1371867Courtesy of GENERAL MOTORS CORP.
  13. Connect the electrical connector to the EVAP canister purge solenoid.
    14. Fig 6: View Of Generator Voltage Regulator
    GM1241861Courtesy of GENERAL MOTORS CORP.
  14. Connect the voltage regulator connector to the generator.
  15. Install the battery harness connector to the generator using a nut.

    Tighten:  Tighten the nut to 15 N.m (11 lb ft).

    16. Fig 7: View Of Oil Pressure Switch
    GM1371908Courtesy of GENERAL MOTORS CORP.
  16. Connect the electrical connector to the oil pressure switch.
    17. Fig 8: Installing Damping Block Connection Nut And Bolt
    GM1242023Courtesy of GENERAL MOTORS CORP.
  17. Install the A/T drive axle. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
  18. Install the rear mounting bracket and the bracket bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  19. Install the damping block connection bolt and nut.

    Tighten:  Tighten the bolt and the nut to 80 N.m (59 lb ft).

    20. Fig 9: View Of Muffler Pipe Nuts
    GM1371911Courtesy of GENERAL MOTORS CORP.
  20. Install the front exhaust pipe and the gasket.
  21. Install the nuts to the front exhaust pipe.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    22. Fig 10: View Of Catalytic Converter Lower Flange Nuts
    GM1371910Courtesy of GENERAL MOTORS CORP.
  22. Install the exhaust front pipe and gasket to the catalytic converter. Secure with the retaining nuts.

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

  23. Secure the exhaust front pipe to the bracket with a bolt.

    Tighten:  Tighten the bolt to 40 N.m (30 lb ft).

  24. Connect the rear HO2S connector.
  25. Connect the A/C compressor coil connector, if equipped.
  26. If the vehicle is equipped with automatic transmission, perform the following procedures:
    1. Connect all of the A/T electrical connectors.
    2. Connect the A/T shift control cable. Refer to Shift Control Cable Replacement - Floor Shift .
    3. Connect the A/T oil cooler inlet/outlet pipe. Refer to Transmission Cooler Pipes and Hoses Replacement (Inlet) or Transmission Cooler Pipes and Hoses Replacement (Outlet) .
    27. Fig 11: Locating A/C Evaporator Pipes
    GM1371928Courtesy of GENERAL MOTORS CORP.
  27. Install the front splash shield and the engine undercover.
  28. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  29. Install the pipe and hose assembly to the A/C compressor, if equipped. Secure with a retaining bolt.

    Tighten:  Tighten the bolt to 33 N.m (24 lb ft).

    30. Fig 12: View Of Lower Radiator Hose
    GM1241850Courtesy of GENERAL MOTORS CORP.
  30. Connect the lower radiator hose to the coolant pipe.
    31. Fig 13: View Of Battery Tray
    GM1241697Courtesy of GENERAL MOTORS CORP.
  31. Install the battery tray support. Secure the support with a bolt.
    32. Fig 14: View Of Fuel Rail
    GM1371864Courtesy of GENERAL MOTORS CORP.
  32. Connect the brake booster vacuum hose at the intake manifold. Connect all of the necessary vacuum lines.
  33. Connect the fuel feed line at the fuel rail.
    34. Fig 15: Locating EGR Valve
    GM1371866Courtesy of GENERAL MOTORS CORP.
  34. Connect the CPS connector.
  35. Connect the oxygen sensor connector.
  36. Connect the electrical connector at the EI system ignition coil
  37. Connect the EGR valve connector.
    38. Fig 16: Identifying Fuel Injector Harness Connectors
    GM1371863Courtesy of GENERAL MOTORS CORP.
  38. Connect the fuel injector connectors.
  39. Connect the surge tank coolant hose at the throttle body.
    40. Fig 17: Spark Plug Wire Routing
    GM1371923Courtesy of GENERAL MOTORS CORP.
  40. Connect the ignition wires to the spark plugs.
    41. Fig 18: Manifold Absolute Pressure (MAP) Sensor
    GM1371862Courtesy of GENERAL MOTORS CORP.
  41. Connect the MAP sensor connector.
    42. Fig 19: View Of Throttle Body And Throttle Cable
    GM1371861Courtesy of GENERAL MOTORS CORP.
  42. Connect the throttle cable to the throttle body and to the intake manifold bracket.
  43. Connect the CMP sensor.
  44. Connect the ACP transducer connector, if equipped.
  45. Connect the TPS connector.
  46. Connect the IAC valve connector.
    47. Fig 20: Identifying Cover Screws
    GM1371851Courtesy of GENERAL MOTORS CORP.
  47. Install the spark plug cover. Install the bolts to the spark plug cover.

    Tighten:  Tighten the bolts to 3 N.m (27 lb in).

  48. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
    49. Fig 21: View Of Air Intake Tube
    GM1272762Courtesy of GENERAL MOTORS CORP.
  49. Connect the air intake tube to the throttle body.
  50. Connect the breather tube to the valve cover.
  51. Connect the IAT sensor connector.
    52. Fig 22: View Of Thermostat Housing Upper Radiator Hose
    GM1371870Courtesy of GENERAL MOTORS CORP.
  52. If the vehicle is equipped with a power steering pump, perform the following procedures:
    1. Connect the power steering pressure hose to the power steering pump.
    2. Install the union nut to the power steering pump.

      Tighten:  Tighten the nut to 28 N.m (21 lb ft).

    3. Connect the power steering return hose to the power steering pump.
  53. Connect the upper radiator hose to the thermostat housing.
  54. Install the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement .
  55. Install the battery and the battery tray. Refer to Battery Tray Replacement .
    56. Fig 23: Locating Fuel Pump Fuse
    GM1291944Courtesy of GENERAL MOTORS CORP.
  56. Install the fuel pump fuse.
  57. Fill the engine crankcase with engine oil.
  58. Fill the engine coolant system. Refer to Draining and Filling Cooling System .
  59. Bleed the power steering system, if equipped. Refer to Power Steering System Bleeding .
  60. Fill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging .
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