Engine Replacement - Suzuki XL7 2007 Service Manual

Engine Replacement

Removal Procedure
1. Remove the battery box and carefully set the engine
control module (ECM) on top of the engine. Refer to
"Battery Box Replacement: ".
2. Disconnect the ECM connector from the under-hood
fuse block.
3. Disconnect ground wire from frame, near battery
box.
4. Remove the fuel injector sight shield. Refer to "Fuel
Injector Sight Shield Replacement".
5. Release the clamp from the brake booster vacuum
hose connection.
6. Disconnect the brake booster vacuum hose from the
intake manifold.
7. Remove the air cleaner assembly. Refer to "Air
Cleaner Assembly Replacement".
8. Discharge the fuel system. Refer to "Fuel Pressure
Relief (With J 34730-1A): " "Fuel Pressure Relief
(Without J 34730-1A): ".
9. Disconnect the evaporative emission (EVAP) hose/
pipe from the EVAP canister purge solenoid valve.
Refer to "Plastic Collar Quick Connect Fitting
Service: ".
10. Disconnect the engine fuel hose/pipe from the
chassis fuel hose/pipe. Refer to "Metal Collar Quick
Connect Fitting Service: ".
11. Discharge the air conditioning (A/C) system. Refer to
"Refrigerant Recovery and Recharging: ".
12. Remove the A/C compressor hose assembly from
the compressor. Cap or plug the hoses and
compressor to prevent contamination. Refer to
"Compressor Hose Assembly Replacement: ".
13. Disconnect the transaxle shift control cable from the
transaxle. Refer to "Shift Control Cable
Replacement: ".
14. Drain the engine coolant from the cooling system.
Refer to "Draining and Filling Cooling System (LY7
GE 47716 Fill): " "Draining and Filling Cooling
System (LY7 Static Fill): ".
15. Tie the radiator, A/C condenser, and fan module
assembly to the upper radiator support to keep the
assembly with the vehicle when the frame and
drivetrain is removed.
16. Disconnect the heater hoses from the engine. Refer
to "Heater Outlet Hose Replacement: ".
17. Remove the radiator inlet hose. Refer to "Radiator
Inlet Hose Replacement: ".
18. Raise and support the vehicle. Refer to "Lifting and
Jacking the Vehicle: ".
19. Remove the radiator outlet hose. Refer to "Radiator
Outlet Hose Replacement: ".
20. Disconnect the transaxle oil cooler lines from the
transaxle and remove the seals. Refer to "Fluid
Cooler Pipe Seal Replacement: ".
21. Cap the transaxle oil cooler lines and plug the
transaxle oil cooler line fittings to prevent loss of
transmission fluid.
22. Remove the catalytic converters and secure the rear
half of the exhaust system to the vehicle underbody.
Refer to "Catalytic Converter Replacement - Left
Side: " and "Catalytic Converter Replacement - Right
Side: ".
23. Remove the front tires. Refer to "Tire and Wheel
Removal and Installation: ".
24. Remove the right and left engine splash shields.
Refer to "Engine Splash Shield Replacement - Left
Side: " and "Engine Splash Shield Replacement -
Right Side: ".
25. Remove the steering intermediate shaft pinch bolt
and discard the bolt.
26. Disconnect the steering intermediate shaft from the
steering gear.
Engine Mechanical: 1D-121