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Engine Assembly Removal and Installation: Removal

WARNING: This page is about a different car, the 2011 Suzuki SX4. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve fuel pressure, see FUEL PRESSURE RELIEF PROCEDURE .
  2. Disconnect negative and positive cables at battery.
  3. Disconnect ECM connectors.
  4. Remove battery and battery tray with ECM.
  5. Remove right and left side engine under covers.
  6. Remove accessory drive belt, see ACCESSORY DRIVE BELT INSPECTION .
  7. Remove front bumper, see FRONT BUMPER AND REAR BUMPER COMPONENTS .
  8. Drain the following oils and fluids if necessary.
  9. Remove air cleaner assembly.
  10. Remove radiator, see RADIATOR REMOVAL AND INSTALLATION .
  11. With hose connected, detach A/C compressor from its bracket.
  12. Disconnect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).
    Fig 1: Disconnecting P/S Fluid Reservoir Hose And P/S Gear Low Pressure Hose
    G06866971Courtesy of SUZUKI OF AMERICA CORP.
  13. Disconnect the following electric wires/connectors and each clamp.
    • Connectors (1) in main fuse box
    • Connector (2) in fuse box No. 1
    • Ground terminal (3) from vehicle body
    • Battery ground cable (4) from transaxle
    • Ground terminal (5) from exhaust manifold
    • Torque sensor (6) (EPS model)
    • P/S motor (7) (EPS model)
      Fig 2: Disconnecting Electric Wires/Connectors And Clamp
      G06866972Courtesy of SUZUKI OF AMERICA CORP.
  14. Disconnect TCM connectors (1), and then pull out engine harness to engine compartment.
    Fig 3: Disconnecting Tcm Connectors
    G06866973Courtesy of SUZUKI OF AMERICA CORP.
  15. Disconnect the following cables, and remove control cable bracket (1).
    • Gear select control cable (2) (M/T model)
    • Gear shift control cable (3) (M/T model)
    • Select cable with select cable bracket (4) (CVT model)
      Fig 4: Identifying Cables And Control Cable Bracket
      G06866974Courtesy of SUZUKI OF AMERICA CORP.
  16. Disconnect the following hoses.
    • Brake booster hose (1) from brake booster
    • Heater inlet and outlet hoses (2) from water outlet cap and heater outlet pipe
    • Fuel feed hose (3) from fuel feed pipe
    • Purge hose (4) from purge valve
    • Clutch hose (5) from clutch fluid pipe (6) (M/T model)
      Fig 5: Disconnecting Hoses
      G06866975Courtesy of SUZUKI OF AMERICA CORP.
  17. Remove right and left drive shaft, see FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  18. Remove exhaust No. 1, No. 2 and center pipe. See EXHAUST SYSTEM COMPONENTS .
  19. Disconnect propeller shaft from transfer (4WD model), see PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
  20. Disconnect steering lower shaft from pinion shaft, see STEERING LOWER SHAFT REMOVAL AND INSTALLATION .
  21. Fix A/C condenser to vehicle body with rope so that A/C condenser does not fall off while lowering engine front mounting member.
  22. Fix transaxle to suspension frame with rope so that engine assembly does not incline while lowering engine assembly.
    Fig 6: Fixing Transaxle To Suspension Frame With Rope
    G06866976Courtesy of SUZUKI OF AMERICA CORP.
  23. Support front suspension frame and engine front mounting member putting jack at hatched parts (1) indicated in figure.
    Fig 7: Supporting Front Suspension Frame And Engine Front Mounting Member
    G06866977Courtesy of SUZUKI OF AMERICA CORP.
  24. Remove engine right mounting nuts (1) and engine left mounting bracket bolt and nuts (2).
    Fig 8: Removing Engine Right Mounting Nuts And Engine Left Mounting Bracket Bolt And Nuts
    G06866978Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove suspension frame mounting bolts (1) and engine front mounting member No. 1 and No. 2 bolts (2).
    Fig 9: Removing Suspension Frame Mounting Bolts And Engine Front Mounting Member No. 1 And No. 2 Bolts
    G06866979Courtesy of SUZUKI OF AMERICA CORP.
  26. Lower engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member.
    CAUTION: When lowering engine, in order to avoid damage to A/C compressor, make clearance by raising A/C compressor.
  27. Disconnect steering gear case from suspension frame, if necessary.
  28. Remove engine with transaxle, transfer (4WD model) from front suspension frame and front lower cross member.
  29. Remove engine harness.
  30. Disconnect transfer (4WD model).
  31. Disconnect transaxle from engine.
  32. Remove clutch cover and clutch disk, if necessary (M/T model), see CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION .
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