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Home >> Geo >> 1990 >> Metro LSi, 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 5 (1.3L 4-CYL - VIN [3] & 1.6L 4-CYL - VIN [0]) >> Removal & Installation >> Engine >> Removal (Samurai)

Removal (Samurai)

WARNING: This page is about a different car, the 1991 Suzuki Swift, 1991 Suzuki Sidekick, and 1991 Suzuki Samurai. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure. See FUEL PRESSURE RELEASE  under REMOVAL & INSTALLATION. Disconnect battery cables. Mark and remove hood. Remove warm air hose. Disconnect breather hose from air cleaner case. Remove air cleaner case from throttle body and air inlet hose.
  2. Mark and disconnect all remaining connectors from throttle body and intake manifold. Disconnect accelerator cable from throttle body. Disconnect and mark wires from starter motor and alternator terminals.
  3. Disconnect fuel supply line and return hoses from throttle body. Disconnect wire connector from oil pressure sending unit and oxygen sensor. Disconnect wire connector from back-up light switch and 5th gear switch.
  4. Disconnect distributor primary lead wires at distributor. Remove high tension wire from ignition coil. Drain radiator. Disconnect hoses from thermostat cap and inlet pipe. Remove cooling fan and clutch.
  5. Remove fan shroud and radiator. Disconnect brake booster vacuum hose. Remove 4 bolts fastening gearshift No. 2 lever boot, and move boot upward. Move gearshift No. 1 to upper side of shift lever.
  6. Loosen 3 bolts on gearshift lever case, and remove shift lever from lever case. Raise vehicle. Disconnect exhaust pipe from exhaust manifold. Disengage clutch cable from clutch release lever. Drain transmission oil.
    NOTE: Install chain hoist on hooks provided. Hooks are located on intake manifold side and exhaust manifold side of engine.
  7. Remove drive shaft connecting transmission case to transfer case. Install chain hoist on provided hooks. One hook is mounted on intake manifold side and another on exhaust manifold side of engine.
  8. Remove exhaust center pipe mounting bracket and 4 transmission mount bolts. Remove pipe connected to chassis under transmission. Lower vehicle. Remove 4 bolts securing right and left engine mounting brackets.
  9. Ensure all hoses, electrical wires and cables are disconnected. Remove engine. Remove clutch lower plate. Separate engine from transmission (if necessary).
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