Throttle Body and Intake Manifold Installation

Install new intake manifold gaskets (1) to cylinder heads.

Fig 1: Installing Intake Manifold Gaskets
Courtesy of SUZUKI OF AMERICA CORP.
Install intake manifold (1) and tighten bolts and nuts.

Fig 2: Installing Intake Manifold Bolts/Nuts
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Install throttle body (2) to intake collector (1) with new throttle body gasket and tighten bolts and nuts.

Fig 3: Installing Throttle Body To Intake Collector
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Install IAC valve (1), EGR valve (2), EVAP canister purge valve (3), manifold absolute pressure sensor, clamps and each hoses to intake collector and throttle body if removed.
NOTE: Use new gasket, when installing IAC valve and EGR valve.

Fig 4: Installing IAC Valve
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Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
Connect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose (5), fuel feed hose (2) and fuel return hose (3).

Fig 5: Installing Throttle Body & Intake Collector Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install EGR pipe (3) with new gaskets.
Connect EVAP canister purge valve hose (4) and heater hose (5).
Connect PCV hose (6), breather hose (8) and water hose (7).
Connect couplers of MAP sensor, EVAP canister purge valve (1) and EGR valve (2). Fix wire harness with clamps.

Fig 6: Installing EGR Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Install clamp bracket (5) to intake collector.
Connect earth terminal (4) to intake collector.
Connect TP sensor coupler (1), MAF sensor coupler (2) and IAC valve coupler (3).

Fig 7: Connecting TP Sensor Coupler
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Connect brake booster hose (2) to intake manifold.
Connect injector wire (1) coupler.

Fig 8: Connecting Injector Wire Coupler
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Connect water hoses (3) to throttle body.
Connect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) to throttle body and adjust these cables, referring to "Accelerator Cable Adjustment and A/T Throttle Cable Adjustment (for A/T Vehicle) ".

Fig 9: Connecting Accelerator Cable & A/T Throttle Cable (For A/T Vehicle) To Throttle Body
Courtesy of SUZUKI OF AMERICA CORP.
Install surge tank pipe (2) to intake manifold with new gaskets and intake air pipe (1) to throttle body.

Fig 10: Installing Surge Tank Pipe To Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.
Install surge tank cover (1).

Fig 11: Installing Surge Tank Cover
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Install air cleaner upper case referring to "AIR CLEANER ELEMENT REMOVAL AND INSTALLATION: ".
Connect coupler to intake air temperature sensor.
Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification.
Tightening torque

Strut tower bar mounting bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 12: Installing Strut Tower Bar Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been reinstalled.
Refill cooling system referring to "COOLING SYSTEM FLUSH AND REFILL ".
Connect negative cable at battery.
Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure described in "FUEL LEAKAGE CHECK PROCEDURE ".