Engine Assembly Removal Suzuki Verona I

Engine Assembly Removal

Tools Required

DW110-060 Engine Assembly Lift Support

DW010-010 Power Pack Stand

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1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant. Refer to «DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257313-S22811448672007070900000) .
9. Remove the engine beautification cover.
10. Remove the air filter snorkel.
11. Remove the air filter housing assembly.
12. Remove the breather hose.
13. Disconnect the coolant reservoir hoses.
14. Remove the coolant reservoir. Refer to «SURGE TANK REMOVAL»(ref-257290-S14034785052007070900000) .
15. Disconnect the power steering pump outlet pipe.
16. Disconnect the fuel rail hose and fuel feeding/return pipe.
17. Disconnect the connectors on the O2S, EGR, charcoal canister purge solenoid valve, MAP sensor, Throttle body, engine oil pressure sensor, CMP sensor, knock sensor, VIS and the engine coolant temperature sensor.
18. Detach wiring harness from the wiring harness bracket on the cylinder block.
19. Disconnect the engine block ground by removing the engine block ground bolts.
20. Remove the battery.
21. Disconnect the automatic transaxle cable.
22. Disconnect the inhibit switch connector.
23. Disconnect the connectors on the transaxle. Refer to «TRANSAXLE ASSEMBLY REMOVAL»(ref-257306-S19054211392007070900000) .
24. Disconnect the generator connector and wiring harness. Refer to «GENERATOR REMOVAL»(ref-257294-S05060234262007070900000) .
25. Remove the upper and lower radiator hoses. Refer to «RADIATOR REMOVAL»(ref-257290-S25696121392007070900000) .
26. Remove the front wheels.
27. Remove the engine under covers.
28. Remove the front axle shaft. Refer to «DRIVE AXLE ASSEMBLY REMOVAL»(ref-257299-S10203536352007070900000) .
29. Remove the front muffler. Refer to «MUFFLER - FRONT REMOVAL»(ref-257291-S17143744012007070900000) .
30. Support the engine assembly using the engine assembly lift support DW110-060.
31. Remove the impact beam. Refer to «IMPACT BEAM REMOVAL»(ref-257288-S41785055042007070900000) .
32. Remove the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.
33. Remove the center front suspension member bolts and the center front suspension member.
34. Disconnect the connector on the compressor.
35. Disconnect the refrigerant suction and discharge pipe block from the compressor.
36. Remove the oil filter.
37. Support the engine and transaxle with the power pack stand DW010-010.
38. Remove the engine mount bracket (RH). Refer to «Engine Mount (RH) Removal»(ref-257287-S12259165242007070900000) .
39. Remove the engine mount bracket (LH). Refer to «Engine Mount (LH) Removal»(ref-257287-S06917748712007070900000) .
40. Separate the engine and transaxle assembly from the engine compartment.
41. Remove the starter. Refer to «STARTER REMOVAL»(ref-257293-S24857688332007070900000) .
42. Remove three (3) transaxle torque converter bolts.
43. Remove the transaxle-to-engine block bolts.
44. Remove the rear transaxle mount bracket.
45. Remove the front damper bush bracket.
46. Remove the engine block-to-transaxle bolts.
47. Remove the engine block-to-transaxle bolts.
48. Remove the engine assembly from the transaxle. CAUTION: Be careful not to damage the torque converter when removing the transaxle.

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1. Installation should follow the removal procedure in the reverse order.
2. Tighten the engine block-to-transaxle bolts near the rear transaxle bracket. Tighten: Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).
3. Tighten the engine block-to-transaxle bolts near the front engine mount bracket. Tighten: Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).
4. Tighten the transaxle-to-engine block bolts near the rear support bracket. Tighten: Tighten the transaxle-to-engine block bolts to 60 - 85 N.m (44 - 63 lb-ft).
5. Tighten the 3 flexible plate-to-torque converter retaining bolts. Tighten: Tighten the transaxle torque converter bolts to 40 - 50 N.m (30 - 37 lb-ft).
6. Install the rear transaxle mount bracket. Tighten: Tighten the rear transaxle mount bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).
7. Install the front damper bush bracket. Tighten: Tighten the front damper bush bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).
8. Install the starter. Refer to «STARTER INSTALLATION»(ref-257293-S16114737922007070900000) .
9. Install the engine and transaxle assembly using the power pack stand DW010-010.
10. Install the engine mount bracket (LH). Refer to «Engine Mount (LH) Installation»(ref-257287-S07425906512007070900000) .
11. Install the engine mount bracket (RH). Refer to «Engine Mount (RH) Installation»(ref-257287-S33241070542007070900000) .
12. Support the engine and transaxle assembly using the engine assembly lift support DW110-060.
13. Remove the power pack stand DW010-010.
14. Install the oil filter. Tighten: Tighten the oil filter to 12 - 16 N.m (106 - 142 lb-in.).
15. Install the center front suspension member. Tighten: Tighten the center front suspension member bolts to 80 - 100 N.m (59 - 74 lb-ft).
16. Tighten the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut. Tighten: Tighten the front engine mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft). Tighten the rear transaxle mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft).
17. Install the front muffler. Refer to «MUFFLER - FRONT INSTALLATION»(ref-257291-S20805229172007070900000) .
18. Install the impact beam. Refer to " «IMPACT BEAM INSTALLATION»(ref-257288-S35833697012007070900000) ".
19. Install the axle shaft. Refer to «DRIVE AXLE ASSEMBLY INSTALLATION»(ref-257299-S20501949482007070900000) .
20. Install the engine under cover. Tighten: Tighten the engine under cover bolts to 17 - 27 N.m (13 - 20 lb-ft).
21. Install the battery. Tighten: Tighten the battery retaining nuts to 4 N.m (35 lb-in.).
22. Connect the connectors and cables on the transaxle. Refer to «TRANSAXLE ASSEMBLY INSTALLATION»(ref-257306-S04299207632007070900000) .
23. Connect the wiring harness, hoses, pipes, and connectors to the engine assembly.
24. Install the coolant reservoir. Refer to «SURGE TANK INSTALLATION»(ref-257290-S37072799822007070900000) . Tighten: Tighten the coolant reservoir bolts to 3.5 - 4.5 N.m (31 - 40 lb-in.).
25. Install the air filter housing. Tighten: Tighten the air filter housing bolt to 8 - 12 N.m (71 - 106 lb-in.).
26. Install the air filter snorkel. Tighten: Tighten the air filter snorkel retaining bolt to 5 - 7 N.m (44 - 62 lb-in.).
27. Install the engine beautification cover. Tighten: Tighten the engine beautification cover bolts to 8 - 12 N.m (71 - 106 lb-in.).
28. Connect the connectors and hoses.
29. Recharge the refrigerant. Refer to «DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257313-S22811448672007070900000) .
30. Fill the power steering oil.
31. Fill the transaxle oil.
32. Fill the engine oil.