Engine Assembly Removal and Installation: Installation

For 5 M/T model, install flywheel if removed. See FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION .
For 4 A/T model, install drive plate if removed. See FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION .
For 5 M/T model, install clutch cover and clutch disc if removed. See CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION .
Install engine harness to engine assembly if removed.
- Tighten engine harness ground bolts with engine harness ground cables to specified torque.
  Tightening torque
  
  Engine harness ground bolt (M6) (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
  
  Engine harness ground bolt (M8) (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
  
  Fig 1: Identifying Engine Harness Ground Bolt
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Fig 2: Identifying Engine Harness Ground Bolt
  Courtesy of SUZUKI OF AMERICA CORP.
  
  Fig 3: Identifying Engine Rear Mounting Member And Front Suspension Frame
  Courtesy of SUZUKI OF AMERICA CORP.
Connect transmission to engine if removed.
- For 5 M/T model: See MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING .
- For 4 A/T model: See AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING .
Lift engine assembly with transmission and transfer (4WD model) into engine compartment using jack.
NOTE:
- Lift engine assembly, transmission, transfer (4WD model), front suspension frame, drive shafts (4WD model), radiator, P/S gear case and engine rear mounting member all together.
- Before lifting engine assembly, make clearance by raising A/C compressor and A/C condenser in order to avoid damage to them.
Tighten engine rear mounting member bolts (2) to specified torque.
Tightening torque

Engine rear mounting member bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
Tighten front suspension frame bolts to specified torque. See FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION .

Fig 4: Identifying Front Suspension Frame Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install steering lower shaft assembly to P/S gear case assembly. See STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
Install tie-rod ends, front drive shafts (4WD model) and ball joints to steering knuckles referring to "Removal" under SUSPENSION CONTROL ARM REMOVAL AND INSTALLATION .
Install stabilizer bar joints to stabilizer bar. See FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS .
Install P/S fluid reservoir to vehicle body.
Install radiator with radiator support bracket and filler neck bracket to vehicle body.
Install A/C condenser assembly to radiator. See A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION .
Install rear propeller shaft. See PROPELLER SHAFT REMOVAL AND INSTALLATION .
Install exhaust pipe No. 2. See EXHAUST SYSTEM COMPONENTS .
For 5 M/T model, install transmission shift control lever to transmission. See TRANSMISSION SHIFT CONTROL LEVER REMOVAL AND INSTALLATION .
For 5 M/T model, connect clutch fluid hose and clutch fluid pipe joint. See CLUTCH FLUID PIPE REMOVAL AND INSTALLATION .
For 4 A/T model, connect A/T select cable to A/T. See SELECT CABLE COMPONENTS .
Install A/C compressor to engine assembly. See COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION .
Install engine harness clamps.
Install all other removed electric wires, connectors and hoses to original locations.
Connect battery ground cable to vehicle body.
Tightening torque

Battery ground terminal bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)

Fig 5: Connecting Battery Ground Cable To Vehicle Body
Courtesy of SUZUKI OF AMERICA CORP.
Install front bumper and radiator grille. See FRONT BUMPER COMPONENTS .
Install accessory drive belt. See ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION .
Install air cleaner assembly and air cleaner outlet hose. See AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION .
Install air cleaner suction pipe. See AIR CLEANER COMPONENTS .
Make sure that all electric wires, connectors and hoses are installed at original locations.
Make sure that all removed components are installed at original locations.
Fill all drained oils and fluids.
- Engine oil: See ENGINE OIL AND FILTER CHANGE .
- Manual transmission oil (5M/T model): See MANUAL TRANSMISSION OIL CHANGE .
- A/T fluid (4 A/T model): A/T FLUID CHANGE .
- P/S fluid: See P/S FLUID CHANGE .
- Transfer oil (4WD model):
  - Motor shift type: See TRANSFER OIL CHANGE .
  - Non-shift type: See TRANSFER OIL CHANGE .
- Front differential oil (4WD model): See FRONT DIFFERENTIAL OIL CHANGE .
Install front tires.
Install engine cover.
Install battery tray and battery bracket.
Install battery. See BATTERY REMOVAL AND INSTALLATION .
Refill cooling system with coolant. See COOLING SYSTEM REFILLING .
Check any leakage of coolant, oil, fuel and exhaust.
- Fuel leak: See FUEL LEAKAGE CHECK PROCEDURE .
- Coolant leak: See ENGINE COOLING SYSTEM INSPECTION .