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Throttle Body and Intake Manifold Removal

  1. Release fuel pressure in fuel feed line by referring to "FUEL PRESSURE RELIEF PROCEDURE ".
    CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.
  2. Disconnect negative cable at battery.
  3. Drain coolant referring to "COOLANT DRAINING ".
  4. Remove strut tower bar.
  5. Disconnect coupler from intake air temperature sensor.
  6. Remove surge tank cover (1).
    Fig 1: Removing Surge Tank Cover
    G02256679Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove air cleaner upper case, intake air hose, intake air pipe (1) and surge tank pipe (2) as one component. Do not disassemble them, when removing and reinstalling.
    Fig 2: Removing Intake Air Pipe & Surge Tank Pipe
    G02256680Courtesy of SUZUKI OF AMERICA CORP.
  8. Disconnect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) from throttle body.
  9. Disconnect water hose (3) from throttle body.
    Fig 3: Disconnecting Accelerator Cable
    G02256681Courtesy of SUZUKI OF AMERICA CORP.
  10. Disconnect injector wire (1) coupler.
  11. Disconnect brake booster hose (2) from intake manifold.
    Fig 4: Disconnecting Injector Wire Coupler
    G02256682Courtesy of SUZUKI OF AMERICA CORP.
  12. Disconnect couplers of TP sensor (1), MAF sensor (2) and IAC valve (3).
  13. Disconnect earth terminal (4) from intake collector.
  14. Remove clamp bracket (5) from intake collector.
    Fig 5: Disconnecting Couplers Of TP Sensor
    G02256683Courtesy of SUZUKI OF AMERICA CORP.
  15. Disconnect couplers from MAP sensor, EVAP canister purge valve (1) and EGR valve (2).
  16. Disconnect PCV hose (6) from cylinder head cover.
  17. Disconnect breather hoses (8) from throttle body or cylinder head cover.
  18. Disconnect EVAP canister purge valve hose (4), water hose (7) and heater hose (5).
  19. Remove EGR pipe (3).
    Fig 6: Removing EGR Pipe
    G02256684Courtesy of SUZUKI OF AMERICA CORP.
  20. Disconnect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose (5), fuel feed hose (2) and fuel return hose (3).
    Fig 7: Disconnecting Heater Hose
    G02256685Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove throttle body (1) and intake collector (2) from intake manifold (3).
    Fig 8: Removing Throttle Body & Intake Collector From Intake Manifold
    G02256686Courtesy of SUZUKI OF AMERICA CORP.
  22. Disconnect IAC valve hose (1) and EVAP canister purge valve hose from intake collector.
  23. Remove throttle body (2) from intake collector.
    Fig 9: Disconnecting IAC Valve Hose & EVAP Canister Purge Valve Hose
    G02256687Courtesy of SUZUKI OF AMERICA CORP.
  24. Remove IAC valve, EGR valve and EVAP canister purge valve from intake collector.
  25. Remove intake manifold bolts (8 pc.) and nuts (4 pc.).
  26. Remove intake manifold.
    Fig 10: Removing Intake Manifold Bolts/Nuts
    G02256688Courtesy of SUZUKI OF AMERICA CORP.
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