LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2009 >> XL7 Limited, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 65 (Engine Mechanical) >> Repair instructions >> Engine Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

WARNING: This page is about a different car, the 2008 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine from the engine stand.
    Fig 1: Identifying Automatic Transaxle Bolts
    G05465399Courtesy of SUZUKI OF AMERICA CORP.
  2. Align the engine to the frame and automatic transaxle.
    CAUTION: Refer to FASTENER NOTICE .
  3. Install the automatic transaxle bolts.

    Tightening torque 

    Tighten the bolts to 75 N.m (55 lb ft)  .

  4. Place a block of wood between the frame and the engine oil pan in order to support the engine on the frame once the engine hoist is removed.
  5. Remove the engine hoist and lift chain.
  6. Remove the engine support adapters from the engine. Refer to ENGINE SUPPORT FIXTURE .
    Fig 2: Identifying Torque Converter Bolts
    G05465400Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the torque converter bolts.

    Tightening torque 

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

  8. Install the starter motor. Refer to STARTER MOTOR REPLACEMENT .
    Fig 3: Identifying Engine To Transaxle Brace And Bolts
    G05465401Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the engine to transaxle brace (3) and bolts (1, 2).

    Tightening torque 

    Tighten the bolts to 50 N.m (37 lb ft)  .

  10. Install the throttle body assembly. Refer to THROTTLE BODY ASSEMBLY REPLACEMENT .
    Fig 4: Identifying Coolant Heater Cord
    G05465402Courtesy of SUZUKI OF AMERICA CORP.
  11. If equipped with an engine coolant heater, connect the coolant heater cord.
    Fig 5: Identifying Engine Electrical Wiring Harness Connector
    G05465403Courtesy of SUZUKI OF AMERICA CORP.
  12. Connect the engine electrical wiring harness to the following components:
    • Transmission module (4)
    • Retainer clips (3, 2)
    • Battery cable (1)

      Tightening torque 

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

      Fig 6: Identifying Engine Electrical Wiring Harness Connector
      G05465404Courtesy of SUZUKI OF AMERICA CORP.
  13. Connect the engine electrical wiring harness to the following components:
    • A/C compressor (8)
    • Oil pressure switch (10)
    • A/C compressor hose (8)
    • Retainer clips (2, 3, 4, 5, 6, 7, 9)
    • Generator (1)

      Tightening torque 

      Tighten the nut to 13 N.m (115 lb in)  .

      Fig 7: Identifying Camshaft Position Actuators And Camshaft Position Sensors
      G05465405Courtesy of SUZUKI OF AMERICA CORP.
  14. Connect the left and right cylinder head engine electrical wiring harness to the following components:
    • Camshaft position actuators (2)
    • Camshaft position sensors (1)
      Fig 8: Identifying Engine Electrical Wiring Harness Connector
      G05465406Courtesy of SUZUKI OF AMERICA CORP.
  15. Connect the engine electrical wiring harness to the following components:
    • Install wire harness to retainers (5, 6, 8, 9)
    • Ground leads (7, 11)
    • Ignition coils (3, 4, 10)
    • EVAP purge solenoid (2)
    • Oxygen sensor (1)
  16. Connect the wiring harness retaining clips near the right and left shock towers.
    Fig 9: Identifying Frame-To-Body Bolts
    G05465407Courtesy of SUZUKI OF AMERICA CORP.
  17. Install NEW frame-to-body bolts.

    Tightening torque 

    Tighten the bolts to 155 N.m (114 lb ft)  .

  18. Install the drivetrain and front suspension frame reinforcement. Refer to DRIVETRAIN AND FRONT SUSPENSION FRAME REINFORCEMENT REPLACEMENT .
  19. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
  20. Lower the vehicle.
    Fig 10: Identifying Bolts That Secure Right Engine Mount To Engine
    G05465408Courtesy of SUZUKI OF AMERICA CORP.
  21. Install the bolts (2) that secure the right engine mount (1) to the engine (3).

    Tightening torque 

    Tighten the bolts to 50 N.m (37 lb ft)  .

  22. Raise the vehicle.
    Fig 11: Identifying Block Of Wood Between Frame And Engine Oil Pan
    G05465409Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove the block of wood (1) between the frame and the engine oil pan used to support the engine while the bolts were removed from the right engine mount.
  24. On all wheel drive (AWD) models, install the rear wheel driveshaft. Refer to REAR WHEEL DRIVE SHAFT REPLACEMENT .
  25. On front wheel drive models, install the right and left front wheel drive shafts into the transaxle. Refer to FRONT WHEEL DRIVE SHAFT REPLACEMENT .
    Fig 12: Identifying Lower Ball Joints And Steering Knuckles
    G05465410Courtesy of SUZUKI OF AMERICA CORP.
  26. On all models, install the right and left lower ball joints to the steering knuckles. Refer to LOWER CONTROL ARM REPLACEMENT .
    Fig 13: Identifying Stabilizer Shaft Links And Stabilizer Shaft
    G05465411Courtesy of SUZUKI OF AMERICA CORP.
  27. Install the right and left stabilizer shaft links to the stabilizer shaft. Refer to STABILIZER SHAFT LINK REPLACEMENT .
    Fig 14: Identifying Tie Rod Ends And Steering Knuckles
    G05465412Courtesy of SUZUKI OF AMERICA CORP.
  28. Install the right and left tie rod ends to the steering knuckles. Refer to RACK AND PINION OUTER TIE ROD END REPLACEMENT .
    Fig 15: Identifying Pinch Bolt And Steering Intermediate Shaft
    G05465413Courtesy of SUZUKI OF AMERICA CORP.
  29. Connect the steering intermediate shaft to the steering gear.
  30. Install a NEW pinch bolt to the steering intermediate shaft.

    Tightening torque 

    Tighten the bolt to 34 N.m (25 lb ft)  .

  31. Install the right and left engine splash shields. Refer to ENGINE SPLASH SHIELD REPLACEMENT - LEFT SIDE and ENGINE SPLASH SHIELD REPLACEMENT - RIGHT SIDE .
  32. Install the front tires. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
  33. Install the catalytic converters. Refer to CATALYTIC CONVERTER REPLACEMENT - LEFT SIDE and CATALYTIC CONVERTER REPLACEMENT - RIGHT SIDE .
    Fig 16: Identifying Transaxle Oil Cooler Lines
    G05465414Courtesy of SUZUKI OF AMERICA CORP.
  34. Install new seals and connect the transaxle oil cooler lines to the transaxle. Refer to FLUID COOLER PIPE SEAL REPLACEMENT .
  35. Install the radiator outlet hose. Refer to RADIATOR OUTLET HOSE REPLACEMENT .
  36. Lower the vehicle.
  37. Install the radiator inlet hose. Refer to RADIATOR INLET HOSE REPLACEMENT .
  38. Connect the heater hoses to the engine. Refer to HEATER OUTLET HOSE REPLACEMENT .
  39. Untie the radiator, AC condenser, and fan module assembly from the upper radiator support.
  40. Connect the transaxle shift control cable to the transaxle. Refer to SHIFT CONTROL CABLE REPLACEMENT .
  41. Install the AC compressor hose assembly to the compressor. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT .
    Fig 17: Identifying Engine Fuel Hose/Pipe And Chassis Fuel Hose/Pipe
    G05465415Courtesy of SUZUKI OF AMERICA CORP.
  42. Connect the engine fuel hose/pipe (3) to the chassis fuel hose/pipe (2). Refer to METAL COLLAR QUICK CONNECT FITTING SERVICE .
  43. Connect the EVAP hose/pipe to the EVAP canister purge solenoid valve. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  44. Install the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT .
    Fig 18: Identifying Brake Booster Vacuum Hose
    G05465416Courtesy of SUZUKI OF AMERICA CORP.
  45. Connect the brake booster vacuum hose (2) to the intake manifold.
  46. Position the clamp (1) on the brake booster vacuum hose connection.
  47. Connect ground wire from frame, near battery box.
  48. Connect the ECM connector to the under-hood fuse block.
  49. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT .
  50. Install the battery box, battery and ECM. Refer to BATTERY BOX REPLACEMENT .
  51. Fill the engine with engine oil. Refer to APPROXIMATE FLUID CAPACITIES , FLUID AND LUBRICANT RECOMMENDATIONS , and MAINTENANCE SCHEDULE (NORTH AMERICAN EMISSIONS) .
  52. Fill the engine with coolant. Refer to COOLING SYSTEM DRAINING AND FILLING (LY7 GE 47716 FILL) or COOLING SYSTEM DRAINING AND FILLING (LY7 STATIC FILL) .
  53. Check the transaxle fluid level. Refer to SEALERS, ADHESIVES, AND LUBRICANTS , TRANSMISSION GENERAL SPECIFICATIONS , and FLUID CAPACITY SPECIFICATIONS .
  54. Charge the AC system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  55. Prime the fuel system.
    1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
    2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    3. If the engine does not start, repeat the steps.
scientia non olet · About LEMON Manuals