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Intake Manifold Installation

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. Installation should follow the removal procedure in the reverse order.
  2. Discard used intake manifold gaskets and install new ones.
  3. Tighten the intake manifold retaining nuts and bolts.
    NOTE: Install the intake manifold after installing the fuel rail.
    CAUTION: Genuine intake manifold retaining bolts within the specifications should be used to prevent damaged intake manifold from impairing the airflow to the cylinder.

    Tighten 

    1. Tighten the seven (7) intake manifold retaining bolts to 10-14 N.m (89-124 lb-in).
    2. Tighten the four (4) intake manifold retaining nuts to 10-14 N.m (89-124 lb-in).
    3. Tighten the two (2) bolts on the intake manifold support bracket to 10-14 N.m (89-124 lb-in).
    4. Fig 1: Tightening Intake Manifold Retaining Nuts & Bolts
    G01985592Courtesy of SUZUKI OF AMERICA CORP.
  4. Tighten the intake EGR pipe retaining bolts on the intake manifold. Refer to EXHAUST GAS RECIRCULATION (EGR) VALVE INSTALLATION .

    Tighten 

    1. Tighten the intake EGR pipe retaining bolts to 8-12 N.m (71-106 lb-in).
    5. Fig 2: Tightening Intake EGR Pipe Retaining Bolts
    G01985593Courtesy of SUZUKI OF AMERICA CORP.
  5. Install the IAT (Intake Air Temperature) sensor. Refer to INTAKE AIR TEMPERATURE (IAT) SENSOR INSTALLATION .

    Tighten 

    1. Tighten the IAT sensor to 20-30 N.m (15-22 lb-ft).
    6. Fig 3: Installing IAT Sensor
    G01985594Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the throttle body assembly. Refer to Throttle Body Assembly Installation  .

    Tighten 

    1. Tighten the throttle body assembly retaining bolts to 8-18 N.m (6-13 lb-ft).
    7. Fig 4: Installing Throttle Body Assembly
    G01985595Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the fuel pressure regulator. Refer to FUEL PRESSURE REGULATOR INSTALLATION .

    Tighten 

    1. Tighten the fuel pressure regulator retaining bolts to 10-13 N.m (89-115 lb-in).
    8. Fig 5: Installing Fuel Pressure Regulator
    G01985596Courtesy of SUZUKI OF AMERICA CORP.
  8. Install the VIS vacuum tank. Refer to VIS VACUUM TANK INSTALLATION .

    Tighten 

    1. Tighten the VIS vacuum tank retaining bolts to 7-9 N.m (62-80 lb-in).
    9. Fig 6: Installing VIS Vacuum Tank
    G01985597Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the air filter snorkel. Refer to Air Intake System Location  .

    Tighten 

    1. Tighten the air filter snorkel retaining bolts to 5-7 N.m (44-62 lb-in).
    10. Fig 7: Installing Air Filter Snorkel
    G01985598Courtesy of SUZUKI OF AMERICA CORP.
  10. Install the engine beautification cover.

    Tighten 

    1. Tighten the engine beautification retaining bolts to 8-12 N.m (71-106 lb-in).
Fig 8: Installing Engine Beautification Cover
G01985599Courtesy of SUZUKI OF AMERICA CORP.
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