Suzuki Vitara, Grand Vitara, XL7 2000-06

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Strut tower bar, if equipped
     
    Cooling fan and shroud
     
    Heater hoses
     
    Radiator hoses
     
    Bypass hose
     
    Radiator
     
    Air intake tube
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Exhaust Gas Recirculation (EGR) valve and temperature sensor
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    Idle Air Control (IAC) valve hoses and connector
     
    Fuel lines
     
    Main engine control wiring harness connectors at the firewall
     
    Throttle Position (TP) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Temperature gauge sender connector
     
    A/C temperature switch, if equipped
     
    Injector harness connectors
     
    Alternator wiring connectors
     
    Manifold Absolute Pressure (MAP) sensor connector and vacuum line
     
    Brake booster vacuum line
     
    Evaporative Emission (EVAP) canister and hoses
     
    Distributor, if equipped
     
    Front skidplate, if equipped
     
    Power steering hoses
     
    A/C compressor, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Clutch cable, if equipped
     
    Transmission cooler lines, if equipped
     
    Exhaust front pipe
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  8.  

To install:

  1. Install or connect the following:

    Engine. Tighten the mount bolts to 40 ft. lbs. (54 Nm).
     
    Transmission flange fasteners. Tighten them to 62 ft. lbs. (85 Nm).
     
    Starter motor
     
    Exhaust front pipe
     
    Transmission cooler lines, if equipped
     
    Clutch cable, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 40 ft. lbs. (54 Nm).
     
    Flywheel access cover
     
    A/C compressor, if equipped
     
    Power steering hoses
     
    Front skidplate, if equipped
     
    Distributor, if equipped
     
    EVAP canister and hoses
     
    Brake booster vacuum line
     
    MAP sensor connector and vacuum line
     
    Alternator wiring connectors
     
    Injector harness connectors
     
    A/C temperature switch, if equipped
     
    Temperature gauge sender connector
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    TP sensor connector
     
    Main engine control wiring harness connectors at the firewall
     
    Fuel lines
     
    IAC valve hoses and connector
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR valve and temperature sensor
     
    PCV valve and hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake tube
     
    Radiator
     
    Bypass hose
     
    Radiator hoses
     
    Heater hoses
     
    Cooling fan and shroud
     
    Strut tower bar, if equipped
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Strut tower bar, if equipped
     
    Cooling fan and shroud
     
    Heater hoses
     
    Radiator hoses
     
    Bypass hose
     
    Radiator
     
    Air intake tube
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Exhaust Gas Recirculation (EGR) valve and temperature sensor
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    Idle Air Control (IAC) valve hoses and connector
     
    Fuel lines
     
    Main engine control wiring harness connectors at the firewall
     
    Throttle Position (TP) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Temperature gauge sender connector
     
    A/C temperature switch, if equipped
     
    Injector harness connectors
     
    Alternator wiring connectors
     
    Manifold Absolute Pressure (MAP) sensor connector and vacuum line
     
    Brake booster vacuum line
     
    Evaporative Emission (EVAP) canister and hoses
     
    Distributor, if equipped
     
    Front skidplate, if equipped
     
    Power steering hoses
     
    A/C compressor, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Clutch cable, if equipped
     
    Transmission cooler lines, if equipped
     
    Exhaust front pipe
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  8.  

To install:

  1. Install or connect the following:

    Engine. Tighten the mount bolts to 40 ft. lbs. (54 Nm).
     
    Transmission flange fasteners. Tighten them to 62 ft. lbs. (85 Nm).
     
    Starter motor
     
    Exhaust front pipe
     
    Transmission cooler lines, if equipped
     
    Clutch cable, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 40 ft. lbs. (54 Nm).
     
    Flywheel access cover
     
    A/C compressor, if equipped
     
    Power steering hoses
     
    Front skidplate, if equipped
     
    Distributor, if equipped
     
    EVAP canister and hoses
     
    Brake booster vacuum line
     
    MAP sensor connector and vacuum line
     
    Alternator wiring connectors
     
    Injector harness connectors
     
    A/C temperature switch, if equipped
     
    Temperature gauge sender connector
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    TP sensor connector
     
    Main engine control wiring harness connectors at the firewall
     
    Fuel lines
     
    IAC valve hoses and connector
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR valve and temperature sensor
     
    PCV valve and hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake tube
     
    Radiator
     
    Bypass hose
     
    Radiator hoses
     
    Heater hoses
     
    Cooling fan and shroud
     
    Strut tower bar, if equipped
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

1.8L, 2.0L And 2.5L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Heater hoses
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator overflow tank
     
    Radiator
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Strut tower bar, if equipped
     
    Air intake assembly
     
    Engine oil dipstick tube
     
    Transmission oil dipstick tube, if equipped
     
    Ignition coil covers
     
    Ignition coil connectors
     
    Injector connectors
     
    Camshaft Position (CMP) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve
     
    Intake manifold ground cable
     
    Evaporative Emission (EVAP) canister purge valve
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Alternator wiring connectors
     
    Oil pressure gauge sender connector
     
    Power Steering Pressure (PSP) switch connector
     
    Alternator bracket ground cable
     
    Brake booster vacuum line
     
    Tank pressure control vacuum valve hose
     
    Fuel lines
     
    EVAP canister
     
    Power steering pump
     
    A/C compressor
     
    Steering shaft lower assembly
     
    Front differential housing, if equipped
     
    Exhaust front pipe and bracket
     
    Transmission oil cooler lines, if equipped
     
    Transmission stiffener brackets, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine
     
    Left and right engine mounts. Tighten the nuts to 36 ft. lbs. (50 Nm).
     
    Transmission flange fasteners. Tighten them to 58 ft. lbs. (80 Nm).
     
    Starter motor
     
    Torque converter. Tighten the bolts to 47 ft. lbs. (65 Nm).
     
    Flywheel access cover
     
    Transmission stiffener brackets. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Transmission oil cooler lines, if equipped
     
    Exhaust front pipe and bracket
     
    Front differential housing, if equipped
     
    Steering shaft lower assembly
     
    A/C compressor
     
    Power steering pump
     
    EVAP canister
     
    Fuel lines
     
    Tank pressure control vacuum valve hose
     
    Brake booster vacuum line
     
    Alternator bracket ground cable
     
    PSP switch connector
     
    Oil pressure gauge sender connector
     
    Alternator wiring connectors
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    EGR valve connector
     
    EVAP canister purge valve
     
    Intake manifold ground cable
     
    IAC valve
     
    MAF sensor connector
     
    TP sensor connector
     
    CKP sensor connector
     
    CMP sensor connector
     
    Injector connectors
     
    Ignition coil connectors
     
    Ignition coil covers
     
    Transmission oil dipstick tube, if equipped
     
    Engine oil dipstick tube
     
    Air intake assembly
     
    Strut tower bar, if equipped
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Radiator
     
    Radiator overflow tank
     
    Cooling fan and shroud
     
    Radiator hoses
     
    Heater hoses
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.0L And 2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Heater hoses
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator overflow tank
     
    Radiator
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Strut tower bar, if equipped
     
    Air intake assembly
     
    Engine oil dipstick tube
     
    Transmission oil dipstick tube, if equipped
     
    Ignition coil covers
     
    Ignition coil connectors
     
    Injector connectors
     
    Camshaft Position (CMP) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve
     
    Intake manifold ground cable
     
    EVAP canister purge valve
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Alternator wiring connectors
     
    Oil pressure gauge sender connector
     
    Power Steering Pressure (PSP) switch connector
     
    Alternator bracket ground cable
     
    Brake booster vacuum line
     
    Tank pressure control vacuum valve hose
     
    Fuel lines
     
    EVAP canister
     
    Power steering pump
     
    A/C compressor
     
    Steering shaft lower assembly
     
    Front differential housing, if equipped
     
    Exhaust front pipe and bracket
     
    Transmission oil cooler lines, if equipped
     
    Transmission stiffener brackets, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine
     
    Left and right engine mounts. Tighten the nuts to 36 ft. lbs. (50 Nm).
     
    Transmission flange fasteners. Tighten them to 58 ft. lbs. (80 Nm).
     
    Starter motor
     
    Torque converter. Tighten the bolts to 47 ft. lbs. (65 Nm).
     
    Flywheel access cover
     
    Transmission stiffener brackets. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Transmission oil cooler lines, if equipped
     
    Exhaust front pipe and bracket
     
    Front differential housing, if equipped
     
    Steering shaft lower assembly
     
    A/C compressor
     
    Power steering pump
     
    EVAP canister
     
    Fuel lines
     
    Tank pressure control vacuum valve hose
     
    Brake booster vacuum line
     
    Alternator bracket ground cable
     
    PSP switch connector
     
    Oil pressure gauge sender connector
     
    Alternator wiring connectors
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    EGR valve connector
     
    EVAP canister purge valve
     
    Intake manifold ground cable
     
    IAC valve
     
    MAF sensor connector
     
    TP sensor connector
     
    CKP sensor connector
     
    CMP sensor connector
     
    Injector connectors
     
    Ignition coil connectors
     
    Ignition coil covers
     
    Transmission oil dipstick tube, if equipped
     
    Engine oil dipstick tube
     
    Air intake assembly
     
    Strut tower bar, if equipped
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Radiator
     
    Radiator overflow tank
     
    Cooling fan and shroud
     
    Radiator hoses
     
    Heater hoses
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Recover the refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain transmission oil or A/T fluid
  12.  
  13. Remove engine hood.
  14.  
  15. Remove battery and battery tray.
  16.  
  17. Remove surge tank cover.
  18.  
  19. Remove air cleaner assembly and air cleaner outlet hose
  20.  
  21. Disconnect the following electric wires.

    MAP sensor
     
    Injector harness
     
    Electric throttle body EVAP canister purge valve
     
    Ignition coil assemblies
     
    CMP sensor
     
    Alternator
     
    Starting motor
     
    Pressure switch of P/S pump
     
    Magnet clutch switch of A/C compressor (if equipped)
     
    Engine oil pressure switch
     
    Ground terminals
     
    Knock sensor
     
    CKP sensor
     
    A/F sensor (No.1 and No.2)
     
    HO2S (No.1 and No.2)
     
    EGR valve
     
    ECT sensor
     
    Back up light switch (for M/T model)
     
    Input shaft speed sensor (for A/T model)
     
    Output shaft speed sensor (for A/T model)
     
    Transmission range sensor (for A/T model)
     
    Transmission wire connector (for A/T model)
     
    Transfer actuator (if equipped)
     
    Center differential switch (if equipped)
     
    4 L/N switch (if equipped)
     
    Each wire harness clamps
     

  22.  
  23. Disconnect the following hoses.

    Brake booster hose from intake manifold
     
    EVAP canister purge hose from fuel No.2 pipe.
     
    Vacuum tank hose from intake manifold
     
    IMT hose from IMT valve
     
    Radiator inlet hose and outlet hose from each pipe
     
    Heater inlet hose and outlet hose from each pipe
     
    Fuel feed hose and return hose from each pipe
     
    Reservoir hose from water outlet cap
     
    Clutch oil pipe from transmission front case (for M/T model)
     
    A/T fluid cooler hose from radiator (for A/T model)
     

  24.  
  25. Disconnect high pressure pipe and suction hose from P/S pump.
  26.  
  27. Disconnect suction hose and discharge hose from A/C compressor.
  28.  
  29. For M/T model, remove shift control lever.
  30.  
  31. For A/T model, disconnect A/T select cable from A/T.
  32.  
  33. Remove exhaust No.1 and No.2 pipes.
  34.  
  35. Remove front and rear propeller shafts.
  36.  
  37. Support front suspension frame and engine rear mounting member using jack
  38.  
  39. Hoist vehicle and remove wheels (right & left).
  40.  
  41. Remove engine under cover.
  42.  
  43. Remove suspension control arm.
  44.  
  45. Remove right side and left side front drive shaft assembly
  46.  
  47. Remove stabilizer joints . When loosening joint nut, hold stud with hexagon wrench.
  48.  
  49. Disconnect steering lower shaft from pinion shaft.
  50.  
  51. Detach low pressure return hose from low pressure return pipe and then disconnect pipe bracket.
  52.  
  53. Remove gear box union bolt.
  54.  
  55. Remove front propeller shaft (if equipped).
  56.  
  57. Fix the radiator to the body with a rope to avoid the radiator from falling off when front suspension frame is lowered.

    Click image to see an enlarged view

    Fig. Radiator fixed position

  58.  
  59. Support engine assemble by using chain hoist.
  60.  
  61. Support suspension frame.

    Click image to see an enlarged view

    Fig. Frame support positions

  62.  
  63. Remove front suspension frame mounting bolts.
  64.  
  65. Remove engine rear mounting member bolts.
  66.  
  67. Before lowering engine, recheck to make sure all hoses, electric wires and cables are disconnected from engine.
  68.  
  69. Lower engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment.
  70.  
  71. Disconnect transmission from engine.
  72.  
  73. Remove engine with engine front mounting bracket from engine front mounting, if necessary.
  74.  
  75. Remove clutch cover and clutch disk if necessary.
  76.  

To install:

  1. Install clutch cover and clutch disk if removed.
  2.  
  3. 2)Install engine with engine front mounting bracket to engine front mounting tighten to 40 ft. lbs (55 Nm).
    NOTE
    Be sure to align dowel pin of engine front mounting with dowel hole of engine front mounting bracket.

  4.  
  5. Connect transmission to engine.
  6.  
  7. Lift engine with transmission, front suspension frame and engine rear mounting member into engine compartment with jack.
  8.  
  9. Tighten engine rear mounting member bolt to 40 ft. lbs (55 Nm).
  10.  
  11. Install suspension frame.
  12.  
  13. Tighten suspension frame mounting bolts to 98 ft. lbs. (135 Nm) and engine front body side mounting nuts to 40 ft. lbs. (55 Nm).
  14.  
  15. Remove chain hoist from engine and the rope from the radiator.
  16.  
  17. Install front propeller shaft (if equipped).
  18.  
  19. Tighten pipe bracket bolts to 8 ft. lbs. (11 Nm) and then insert low pressure return hose to low pressure return pipe.
  20.  
  21. Tighten union gear box bolt to 25.5 ft. lbs. (35 Nm).
  22.  
  23. Connect steering lower shaft from pinion shaft Steering.
  24.  
  25. Install stabilizer joints, and tighten nuts to 43.5 ft. lbs. (60 Nm). When tightening, hold stud with hexagon wrench.
  26.  
  27. Install right side and left side front drive shaft assembly (if equipped).
  28.  
  29. Install suspension control arm.
  30.  
  31. Install engine under cover.
  32.  
  33. Install wheels (right & left) and lower hoist.
  34.  
  35. Remove engine jack.
  36.  
  37. Install front and rear propeller shafts (if equipped).
  38.  
  39. Install exhaust No.1 and No.2.
  40.  
  41. Connect suction hose and discharge hose to A/C compressor
  42.  
  43. Connect high pressure pipe and suction hose from P/S pump
  44.  
  45. Return disconnected hoses, cables and electric wire.
  46.  
  47. Check all removed parts are back in place.
  48.  
  49. For A/T model, adjust select cable.
  50.  
  51. Refill transmission with correct fluid.
  52.  
  53. Refill and bleed power steering system.
  54.  
  55. Refill cooling system with coolant.
  56.  
  57. Refill engine with engine oil.
  58.  
  59. Bleed air from clutch system (if equipped).
  60.  
  61. Install surge tank cover.
  62.  
  63. Install battery tray and battery.
  64.  
  65. Install engine hood.
  66.  
  67. Vacuum and recharge A/C system.
  68.  
  69. With engine OFF, turn ignition switch to ON position and check for fuel leakage.
  70.  
  71. Start engine and check coolant, oil and exhaust gas leakage at each connection.
  72.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Recover the refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove engine hood.
  12.  
  13. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir.
  14.  
  15. Disconnect accelerator cable from throttle body.
  16.  
  17. Detach fuse/relay box, then remove strut tower bar and surge tank cover.
  18.  
  19. Disconnect IAT sensor coupler and MAF sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.
  20.  
  21. Remove intake control valve.
  22.  
  23. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
  24.  
  25. Remove ignition coil covers.
  26.  
  27. Disconnect the following electric lead wires:

    Injector wire coupler
     
    Camshaft Position Sensor(CMP) sensor coupler
     
    Ignition coil couplers
     
    Crankshaft Position Sensor(CKP) sensor coupler
     
    Manifold Absolute Pressure (MAP) sensor coupler
     
    Throttle Position (TP) sensor coupler
     
    Idle Air Control (IAC) valve coupler
     
    Earth wire from surge tank
     
    Evaporative Emissions Canister(EVAP) canister purge valve coupler
     
    Exhaust Gas Recirculation (EGR) valve coupler
     
    Oxygen sensors
     
    Coolant temperature sensor coupler
     
    Knock sensor coupler
     
    Generator wires
     
    Starter wires
     
    Oil pressure wire
     
    P/S pump wire
     
    Earth wire from generator bracket
     
    Engine block heater (if equipped)
     

  28.  
  29. Disconnect the following hoses:

    Heater hose from heater water pipe and water outlet cap
     
    Tank pressure control solenoid valve hose from intake manifold
     
    EVAP canister hose from canister purge pipe
     
    Brake booster vacuum hose
     

  30.  
  31. Remove EVAP canister purge valve.
  32.  
  33. Disconnect the following hoses at the location shown in figure:

    Fuel feed hose from fuel feed pipe
     
    Fuel return hose from fuel return pipe
     

  34.  
  35. Remove P/S pump assembly.
  36.  
  37. Remove A/C compressor assembly.
  38.  
  39. Remove steering shaft lower assembly.
  40.  
  41. Raise vehicle.
  42.  
  43. Remove front differential housing with differential from chassis if equipped.
  44.  
  45. Remove front exhaust pipe.
  46.  
  47. Remove exhaust manifold stiffener from transmission.
  48.  
  49. Remove A/T fluid hose clamps from engine mounting bracket (for A/T vehicle).
  50.  
  51. Remove clutch housing lower plate.
  52.  
  53. Remove torque converter bolts (for A/T vehicle).
  54.  
  55. Remove starter motor.
  56.  
  57. Lower vehicle.
  58.  
  59. Support transmission.
  60.  
  61. Remove bolts and nuts fastening cylinder block and transmission.
  62.  
  63. Install lifting device.
  64.  
  65. Disconnect engine side mounting brackets from engine mountings by removing nuts.
  66.  
  67. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
  68.  
  69. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.
  70.  

To install:

  1. Reverse removal procedure for installation noting the following points.
  2.  
  3. Tighten engine side mounting bracket nuts to 40 ft. lbs (55 Nm).

    Click image to see an enlarged view

    Fig. Engine and mounting brackets

  4.  
  5. Tighten transmission case bolts and nut 61.5 ft. lbs. (85 Nm) (for M/T vehicle).
  6.  
  7. Tighten Transmission case bolt and nut 58 ft. lbs. (80 Nm) (for A/T vehicle).
  8.  
  9. Tighten torque converter bolts to 47 ft. lbs. (65 Nm).
  10.  
  11. Tighten bolts and nuts of exhaust pipe to 36.5 ft. lbs. (50 Nm).
  12.  
  13. Install front differential housing with differential to chassis.
  14.  
  15. Install steering shaft lower assembly.
  16.  
  17. Install A/C compressor assembly.
  18.  
  19. Install P/S pump assembly.
  20.  
  21. Adjust accelerator cable play.
  22.  
  23. Refill engine with engine oil.
  24.  
  25. Refill cooling system.
  26.  
  27. Check to ensure that all fasteners and clamps are tightened.
  28.  
  29. Vacuum and recharge A/C system.
  30.  
  31. Upon completion of installation, verify that there is no fuel leakage, coolant leakage, P/S fluid leakage or exhaust gas leakage at each connection.
  32.  

 
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