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Home >> Suzuki >> 1992 >> Sidekick JS, 4D Utility >> Repair and Diagnosis >> External Pages >> Different car >> Section 53 (Engine Mechanical) >> Repair Instructions >> Upper Intake Manifold Replacement >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Installing Upper Intake Manifold And Gasket
G04841456Courtesy of SUZUKI OF AMERICA CORP.
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the upper intake manifold.
    CAUTION: Refer to FASTENER NOTICE .
  3. Apply threadlock to the bolt threads. Refer to SEALERS, ADHESIVES, AND LUBRICANTS . Install the upper intake manifold bolts.

    Tightening torque 

    Tighten the bolts to 25 N.m (18 lb ft)  .

  4. If the upper manifold was replaced, complete the following steps:
    1. Install the throttle body. Refer to INSTALLATION PROCEDURE .
    2. Install the EVAP purge solenoid valve. Refer to INSTALLATION PROCEDURE .
      Fig 2: Identifying Engine Harness Retaining Clips
      G04841457Courtesy of SUZUKI OF AMERICA CORP.
  5. Install the engine harness retaining clips.
  6. Install the brake booster vacuum hose to the intake manifold.
  7. Install the brake booster vacuum hose to the intake manifold.
    Fig 3: Identifying Bleed Pipe Bolts
    G04841458Courtesy of SUZUKI OF AMERICA CORP.
  8. Position the bleed pipe.
  9. Install the bleed pipe hose clamp (2).
  10. Install the bleed pipe bolts (1).

    Tightening torque 

    Tighten the nut to 10 N.m (89 lb in)  .

  11. Connect the coolant hose bleed pipe (4).
    Fig 4: Connecting EVAP Canister Purge Line
    G04841459Courtesy of SUZUKI OF AMERICA CORP.
  12. Connect the EVAP canister purge line (3).
    Fig 5: Connecting PCV Line To Top Of Intake Manifold
    G04841460Courtesy of SUZUKI OF AMERICA CORP.
  13. Connect the PCV line (2) to the top of the intake manifold.
    Fig 6: Connecting ETC Electrical Connector
    G04841461Courtesy of SUZUKI OF AMERICA CORP.
  14. Connect the ETC electrical connector.
  15. Install the air cleaner outlet duct.
    Fig 7: Installing Fresh Air PCV Line To Air Cleaner Inlet Duct
    G04841462Courtesy of SUZUKI OF AMERICA CORP.
  16. Install the fresh air PCV line (1) to the air cleaner inlet duct.
  17. Install the engine cover. Refer to INSTALLATION PROCEDURE .
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