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Intake Manifold Removal

WARNING: This page is about a different car, the 2004 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
    5. Fig 1: Draining Engine Coolant
    G01985581Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove the engine beautification cover retaining nut and engine beautification cover.
  6. Remove the air filter snorkel.
    7. Fig 2: Removing Air Filter Snorkel
    G01985582Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the VIS vacuum tank.
    8. Fig 3: Removing VIS Vacuum Tank
    G01985583Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the fuel pressure regulator.
    9. Fig 4: Removing Fuel Pressure Regulator
    G01985584Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove the breather hose.
  10. Remove the PCV vacuum hose.
    11. Fig 5: Removing PCV Vacuum Hose
    G01985585Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove the air filter outlet hose. Refer to Air Intake System Location  .
  12. Remove the throttle body assembly. Refer to Throttle Body Assembly Removal  .
    13. Fig 6: Removing Throttle Body Assembly
    G01985586Courtesy of SUZUKI OF AMERICA CORP.
  13. Disconnect the charcoal canister purge solenoid connector and hose. Refer to Air Intake System Location  .
  14. Disconnect the O2S (Oxygen Sensor) connector. Refer to OXYGEN SENSOR (O2S) REMOVAL .
  15. Disconnect the MAP (Manifold Absolute Pressure) sensor connector. Refer to MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL .
  16. Disconnect the CKP (Crankshaft Position) sensor connector. Refer to CRANKSHAFT POSITION (CKP) SENSOR REMOVAL .
    17. Fig 7: Disconnecting CKP Sensor Connector
    G01985587Courtesy of SUZUKI OF AMERICA CORP.
  17. Disconnect the EGR (Exhaust Gas Recirculation) solenoid connector. Refer to EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL .
  18. Disconnect the CMP (Camshaft Position) sensor connector. Refer to CAMSHAFT POSITION (CMP) SENSOR REMOVAL .
  19. Remove the IAT (Intake Air Temperature) sensor. Refer to INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL .
  20. Disconnect the ignition coil connector. Refer to IGNITION COIL REMOVAL .
  21. Remove the vacuum hose on the brake booster.
    22. Fig 8: Removing Vacuum Hose On Brake Booster
    G01985588Courtesy of SUZUKI OF AMERICA CORP.
  22. Remove the EGR pipe from the intake manifold.
  23. Remove the engine coolant temperature sensor.
    24. Fig 9: Removing Engine Coolant Temperature Sensor
    G01985589Courtesy of SUZUKI OF AMERICA CORP.
  24. Remove the wiring harness from the support bracket on the cylinder block.
    25. Fig 10: Removing Wiring Harness From Support Bracket On Cylinder Block
    G01985590Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove the intake manifold retaining nuts/bolts and the intake manifold.
  26. Remove the bolts on the intake manifold support bracket.
  27. Remove the intake manifold gaskets.
  28. Clean the contact surfaces between intake manifold and the cylinder head.
    NOTE: Remove the fuel rail after removing the intake manifold.
Fig 11: Cleaning Contact Surfaces Between Intake Manifold & Cylinder Head
G01985591Courtesy of SUZUKI OF AMERICA CORP.
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