Intake Manifold Removal and Installation: Removal

Disconnect negative cable at battery.
Drain cooling system.
WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

Fig 1: Identifying Radiator Drain Plug
Courtesy of SUZUKI OF AMERICA CORP.
Remove engine cover referring to ENGINE COVER REMOVAL AND INSTALLATION .
Remove air cleaner outlet hose referring to AIR CLEANER OUTLET HOSE REMOVAL AND INSTALLATION .
Disconnect accelerator cable (2) from throttle valve lever (1).
Disconnect accelerator cable (2) with cable bracket (3) from intake manifold.
Disconnect the following electric lead wires:
- IAC valve coupler (4)
- TP sensor coupler (5)
- EGR valve coupler (6)
- EVAP canister purge valve coupler (7)
- MAP sensor coupler (8)
- Ground terminal (9) from throttle body
Disconnect the following hoses:
- Brake booster hose (10) from intake manifold
- PCV hose (11) from PCV valve
- Fuel pressure regulator vacuum hose (12) from intake manifold
- Coolant hoses from (13) throttle
- Breather hose (14) from throttle body
- Vacuum hose (15) from EVAP canister purge valve
Remove intake manifold front stiffener (16).

Fig 2: Removing Intake Manifold Front Stiffener (16)
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear stiffener (17), and disconnect coolant pipe (18) from intake manifold.

Fig 3: Removing Intake Manifold Rear Stiffener
Courtesy of SUZUKI OF AMERICA CORP.
Remove intake manifold (2) with throttle body from cylinder head, and then its gasket (1).

Fig 4: Removing Intake Manifold With Throttle Body From Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.