Engine Assembly: Removal and Installation: Removal

Preparation 

1. Remove front and rear engine under covers, if equipped. Refer to FRONT BUMPER: REMOVAL AND INSTALLATION .
2. Drain engine oil. Refer to [ENGINE OIL: CHANGE [VQ40DE] ].
3. Remove engine oil filter.
4. Drain engine coolant. Refer to [CHANGING ENGINE COOLANT ].
5. Partially drain A/T fluid. Refer to [CHANGING THE A/T FLUID (ATF) ].
   NOTE: Cap or plug opening(s) to prevent fluid from spilling.
6. Release fuel pressure. Refer to [FUEL PRESSURE CHECK: VQ40DE ].
7. Remove the engine hood. Refer to [HOOD ASSEMBLY: REMOVAL AND INSTALLATION ].
8. Disconnect the battery negative terminal. Refer to [BATTERY: REMOVAL AND INSTALLATION ].
9. Remove engine room cover using power tools. Refer to ENGINE ROOM COVER: REMOVAL AND INSTALLATION .
10. Remove the air duct and air cleaner case assembly. Refer to [AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION ].
11. Disconnect vacuum hose between vehicle and engine and set it aside.
12. Remove front grille. Refer to [FRONT GRILLE: REMOVAL AND INSTALLATION ].
13. Remove the radiator assembly and hoses. Refer to [RADIATOR: REMOVAL AND INSTALLATION ].
    NOTE: Cap or plug opening(s) to prevent fluid from spilling.
14. Remove the drive belts. Refer to [DRIVE BELTS: REMOVAL AND INSTALLATION ].
15. Remove the engine cooling fan. Refer to [ENGINE COOLING FAN: REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE) ]
16. Disconnect the engine room harness from the engine side and set it aside.
17. Disconnect the engine harness grounds.
18. Disconnect the reservoir tank for power steering from engine and move it aside.
19. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope. Refer to [POWER STEERING OIL PUMP: REMOVAL AND INSTALLATION ]
20. Remove the A/C compressor bolts and set aside. Refer to [COMPRESSOR: REMOVAL AND INSTALLATION ]
21. Disconnect EVAP line.
22. Disconnect the fuel hose at the engine side connection. Refer to [FUEL INJECTOR AND FUEL TUBE: REMOVAL AND INSTALLATION [VQ40DE] ]
    NOTE: Cap or plug opening(s) to prevent fluid from spilling.
23. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
    NOTE: Cap or plug opening(s) to prevent fluid from spilling.
24. Remove the A/T oil level indicator and indicator tube.
    NOTE: Cap or plug opening(s) to prevent fluid from spilling.
25. Remove front final drive assembly (4WD models). Refer to [FRONT FINAL DRIVE ASSEMBLY: REMOVAL AND INSTALLATION ]
26. Remove three way catalyst. Refer to [EXHAUST MANIFOLD AND THREE WAY CATALYST: REMOVAL AND INSTALLATION [VQ40DE] ]
27. Install engine slingers into left bank and right bank.
    Fig 1: Installing Engine Slingers Into Left Bank And Right Bank

    Courtesy of SUZUKI OF AMERICA CORP.

    Engine slinger torque: 28.0 N.m (2.9 kg-m, 21 ft-lb) 

28. Remove front frame crossmember.
29. Remove transmission. Refer to [TRANSMISSION ASSEMBLY: REMOVAL AND INSTALLATION FROM VEHICLE ] (2WD M/T models) [TRANSMISSION ASSEMBLY: REMOVAL AND INSTALLATION FROM VEHICLE ] (4WD M/T models), [TRANSMISSION ASSEMBLY: REMOVAL AND INSTALLATION FOR VQ40DE 2WD MODELS ] (2WD A/T models), [TRANSMISSION ASSEMBLY: REMOVAL AND INSTALLATION FOR VQ40DE 4WD MODELS ] (4WD A/T models).
30. Remove engine mounting insulator bracket (upper) with power tool.
31. Lift with hoist and secure the engine in position.
32. Remove engine mount bracket bolts.
33. Remove engine assembly from vehicle, avoiding interference with vehicle body.
    CAUTION:

    • Before and during this lifting, always check if any harnesses are left connected.
34. Remove the parts that may restrict installation of engine to engine stand.
    NOTE: The procedure is described assuming that you use a engine holding the surface, to which transmission is installed.
    1. Remove clutch cover and clutch disc (M/T models). Refer to CLUTCH DISC, CLUTCH COVER: REMOVAL AND INSTALLATION [6M/T]
    2. Remove flywheel (M/T models) or drive plate (A/T models).
       • Holding crankshaft pulley bolts, lock crankshaft to remove flywheel or drive plate bolts.
       • Loosen bolts diagonally.
         CAUTION:

         • Be careful not to damage drive plate. Especially avoid deforming and damaging of signal plate teeth (circumference position).
           Fig 2: Identifying Signal Plate Teeth

           Courtesy of SUZUKI OF AMERICA CORP.
         • Do not disassemble drive plate.
         • Place the drive plate with signal plate surface facing other than downward.
         • Keep magnetic materials away from signal plate.
         CAUTION: Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough for supporting the engine weight.

         • If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand.
           • Remove fuel tube and fuel injector assembly. Refer to [FUEL INJECTOR AND FUEL TUBE: REMOVAL AND INSTALLATION [VQ40DE] ].
           • Remove intake manifold. Refer to [INTAKE MANIFOLD: REMOVAL AND INSTALLATION ].
           • Remove rocker cover. Refer to [ROCKER COVER: REMOVAL AND INSTALLATION ].
           • Other removable brackets.
         CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.