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Engine Assembly Removal and Installation: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Using lifting device, support engine.
  2. Install front suspension frame to engine. See FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION .
  3. Install A/C compressor. See COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION .
  4. Install P/S pump. See P/S PUMP REMOVAL AND INSTALLATION .
  5. Install generator. See GENERATOR REMOVAL AND INSTALLATION .
  6. Install starting motor. See STARTING MOTOR REMOVAL AND INSTALLATION .
  7. Install exhaust manifold. See EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A) .
  8. Install intake manifold. See INTAKE MANIFOLD REMOVAL AND INSTALLATION .
  9. Connect transmission to engine (5A/T model). See AUTOMATIC TRANSMISSION UNIT COMPONENTS .
  10. Connect high pressure hose and suction hose to P/S pump. See P/S HOSE/PIPE COMPONENTS .
  11. Install engine harness to engine, transmission and transfer.
  12. Lift engine with transmission, transfer, front suspension frame and engine rear mounting member into engine compartment. See ENGINE MOUNTINGS COMPONENTS .
  13. Tighten front suspension frame bolt. See FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS .
  14. Remove engine jack.
  15. Connect select cable to transmission range sensor and bracket (5A/T model). See SELECT CABLE COMPONENTS .
  16. Install front drive shaft. See FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  17. Install front propeller shaft (4WD model) and rear propeller shaft. See PROPELLER SHAFT REMOVAL AND INSTALLATION .
  18. Install exhaust center pipe and exhaust No. 1 pipe. See EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION .
  19. Connect steering lower shaft assembly to pinion shaft of P/S gear case assembly. See STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  20. Install liquid pipe (1) to condenser. See A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION .
  21. Install front bumper. See FRONT BUMPER COMPONENTS .
  22. Connect suction hose and discharge hose to compressor. See COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION .
  23. Put back disconnected hoses, cables and electric wires for connection noting the following.
    • Tighten ground terminal bolts to specified torque.

      Tightening torque 

      Ground terminal bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) 

      Fig 1: Identifying Ground Terminal Bolt
      G06492994Courtesy of SUZUKI OF AMERICA CORP.
      Fig 2: Identifying Ground Terminal Bolt
      G06492995Courtesy of SUZUKI OF AMERICA CORP.
  24. Install glove box (1) and instrument panel under cover (2).
    Fig 3: Identifying Glove Box And Instrument Panel Under Cover
    G06492996Courtesy of SUZUKI OF AMERICA CORP.
  25. Install air cleaner assembly and air cleaner suction pipe. See AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION .
  26. Check to ensure that all removed parts are back in place.
  27. Evacuate and charge the A/C system. See OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT .
  28. Refill P/S system. See P/S FLUID CHANGE .
  29. Refill cooling system with coolant. See COOLING SYSTEM REFILLING .
  30. Refill transfer (4WD model). See TRANSFER OIL CHANGE .
  31. Refill front differential (4WD model). See FRONT DIFFERENTIAL OIL CHANGE .
  32. Refill A/T (5A/T model). See A/T FLUID CHANGE .
  33. Refill engine with engine oil. See ENGINE OIL AND FILTER CHANGE .
  34. Install engine front under cover and engine rear under cover.
  35. Install engine cover.
  36. Connect ECM connectors. See ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION .
  37. Install battery.
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