Intake Manifold Removal and Installation: Installation

Install new intake manifold gasket (1) to cylinder head.
Install intake manifold (2) with throttle body. Tighten bolts and nuts to specified torque.
Tightening torque

Intake manifold bolt and nut (a): 25 N.m (2.5 kg-m, 18.0 lb-ft)

Fig 1: Installing Intake Manifold With Throttle Body & New Gasket
Courtesy of SUZUKI OF AMERICA CORP.
Connect coolant pipe (1) to intake manifold and install rear stiffener (2). Tighten bolts to specified torque.
Tightening torque

Intake manifold rear stiffener bolt (a): 25 N.m (2.5 kg-m, 18.0 lb-ft)

Fig 2: Installing Rear Stiffener
Courtesy of SUZUKI OF AMERICA CORP.
Install intake manifold front stiffener (1). Tighten bolts to specified torque.
Tightening torque

Intake manifold front stiffener bolt (a): 55 N.m (5.5 kg-m, 40.0 lb-ft)
Connect the following hoses:
- Brake booster hose (2) to intake manifold
- PCV hose (3) to PCV valve
- Fuel pressure regulator vacuum hose (4) to intake manifold
- Coolant hoses (5) to throttle body
- Breather hose (6) to throttle body
- Vacuum hose (7) to EVAP canister purge valve
Connect the following electric lead wires:
- IAC valve (8)
- TP sensor (9)
- EGR valve (10)
- EVAP canister purge valve (11)
- MAP sensor (12)
- Ground terminal (13) to throttle body
Connect accelerator cable (14) to throttle valve lever (15) and install its bracket (16) to intake manifold. Adjust accelerator cable play. Accelerator Cable Adjustment .

Fig 3: Adjusting Accelerator Cable
Courtesy of SUZUKI OF AMERICA CORP.
Install air cleaner outlet hose. Air Cleaner Outlet Hose Removal and Installation .
Install engine cover. Engine Cover Removal and Installation
Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
Refill cooling system. Refer to COOLING SYSTEM FLUSH AND REFILL .
Connect negative cable at battery.
Start engine and check for engine coolant leaks.