Mechanics

REMOVING ENGINE BLOCK

1999 Suzuki Swift

Engine Mechanical problem
1999 Suzuki Swift 4 cyl Front Wheel Drive Manual 145000 miles

What would be the best process to follow when removing the engine block?
Avatar
013052
January 31, 2009.




Removal (Swift)
Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect battery cables. Remove battery, battery tray and hood (disconnect windshield washer hose from hood). Drain coolant and remove radiator hoses. DO NOT remove drain plug and radiator cap while engine and radiator are still hot. Remove air cleaner and air cleaner outlet hose.
Disconnect the following cables: Accelerator cable from throttle body.
A/T throttle pressure control cable from A/T.
Clutch cable from transmission (M/T).
Gear select cable from transmission (A/T).
Disconnect following electric wires: Ignition coil assembly
Ground wires from surge tank
Engine oil pressure switch
EVAP canister purge valve (if equipped)
Engine coolant temp. Sensor
Fuel injectors
Power steering pressure switch (if equipped)
Oxygen sensor-1
Back-up light switch (M/T)
Transmission range switch (A/T)
A/T vehicle speed sensor (A/T)
Generator
Starter
Battery negative cable from transmission
TP sensor
IAC valve
CMP sensor
MAP sensor and then release wire harnesses from clamps.
Disconnect the following hoses: Canister purge hose from EVAP canister purge valve
Brake booster hose from intake manifold
Radiator outlet hose from inlet pipe
Heater inlet and outlet hose from heater unit
Disconnect fuel feed and return hoses from fuel delivery pipe. Remove exhaust No. L pipe (if equipped) and exhaust pipe. Remove right and left engine under covers. Remove gear shift control shaft from transmission and remove extension rod (M/T).
For A/T vehicle, disconnect A/T select cable from A/T. Drain engine and transmission oil. Disconnect drive shaft joints from differential gears of transmission or center bearing support. In this case, it is not necessary to disconnect drive shafts from steering knuckle.
With hoses connected, detach A/C compressor and/or P/S pump with bracket from cylinder block, if equipped. Suspend removed compressor and/or pump at a place where no damage will be caused during removal and installation of engine with transmission. Disconnect P/S hose from P/S oil pump. (If equipped). Plug pipe, hose and pump port.
Install lifting device. Remove rear mounting from body. (For M/T model). Remove rear torque rod (For A/T model). Remove engine left mounting from body. Remove engine right mounting from right mounting bracket and stiffener.
Before removing engine with transmission from body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transmission. Lower engine with transmission from body.
Installation
Lift engine with transmission into engine compartment, but do not remove lifting device. Install engine right mounting to right mounting bracket and stiffener. Install engine left mounting to body. Install rear mounting to body (For M/T model). Install torque rod (For A/T model). Tighten bolts and nuts of all parts installed in previous steps to 50 ft. Lbs. (55 N.M).
Remove lifting device. Reverse removal procedures for installation of remainder. Push in each axle shaft joint fully so that snap ring engages with differential gear or center bearing support. DO NOT damage oil seal lip when inserting axle shafts. Reclamp electric wire securely.
Adjust clutch pedal free travel. (M/T). Adjust gear select cable and A/T throttle pressure control cable. (A/T). Adjust gear shift control lever. (M/T). Adjust accelerator cable play. Refill transmission with gear oil. (A/T fluid for A/T model). Refill engine with engine oil. Refill cooling system.
Upon completion of installation, verify that there is no fuel leakage, coolant leakage, transmission oil leakage or exhaust gas leakage at each connection.

Dave H
May 3, 2009.


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