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Installation Procedure

WARNING: This page is about a different car, the 2007 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: Aligning Engine To Frame & Automatic Transaxle
    G04841619Courtesy 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: Installing Torque Converter Bolts
    G04841620Courtesy 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 INSTALLATION PROCEDURE .
    Fig 3: Installing Engine To Transaxle Brace & Bolts
    G04841621Courtesy 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 INSTALLATION PROCEDURE .
    Fig 4: Identifying Engine Coolant Heater
    G04841622Courtesy of SUZUKI OF AMERICA CORP.
  11. If equipped with an engine coolant heater, connect the coolant heater cord.
    Fig 5: Connecting Engine Wiring Harness Electrical Connector
    G04841623Courtesy 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: Connecting Engine Wiring Harness Electrical Connector
      G04841624Courtesy 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: Connecting Cylinder Head Engine Wiring Harness Electrical Connector
      G04841625Courtesy 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: Connecting Engine Wiring Harness Electrical Connector
      G04841626Courtesy 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
    G04841627Courtesy 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 INSTALLATION PROCEDURE .
  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: Securing Right Engine Mount To Engine
    G04841628Courtesy 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 & Engine Oil Pan
    G04841629Courtesy 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 INSTALLATION PROCEDURE .
  25. On front wheel drive models, install the right and left front wheel drive shafts into the transaxle. Refer to INSTALLATION PROCEDURE and INSTALLATION PROCEDURE .
    Fig 12: Installing Lower Ball Joints To Steering Knuckles
    G04841630Courtesy of SUZUKI OF AMERICA CORP.
  26. On all models, install the right and left lower ball joints to the steering knuckles. Refer to INSTALLATION PROCEDURE .
    Fig 13: Identifying Stabilizer Shaft Links
    G04841631Courtesy 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
    G04841632Courtesy 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
    G04841633Courtesy 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 INSTALLATION PROCEDURE .
  33. Install the catalytic converters. Refer to INSTALLATION PROCEDURE and INSTALLATION PROCEDURE .
    Fig 16: Connecting Transaxle Oil Cooler Lines To Transaxle
    G04841634Courtesy of SUZUKI OF AMERICA CORP.
  34. Install new seals and connect the transaxle oil cooler lines to the transaxle. Refer to INSTALLATION PROCEDURE .
  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 INSTALLATION PROCEDURE .
  41. Install the AC compressor hose assembly to the compressor. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT .
    Fig 17: Connecting Engine Fuel Hose/Pipe To Chassis Fuel Hose/Pipe
    G04841635Courtesy 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 INSTALLATION PROCEDURE .
    Fig 18: Connecting Brake Booster Vacuum Hose To Intake Manifold
    G04841636Courtesy 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 INSTALLATION PROCEDURE .
  50. Install the battery box, battery and ECM. Refer to INSTALLATION PROCEDURE .
  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 DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL) and DRAINING AND FILLING COOLING SYSTEM (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.
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