Intake Manifold Removal and Installation: Removal

Remove the fuel pump fuse.
Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
Disconnect the negative battery cable.
Disconnect the Charcoal Canister Purge (CCP) and Exhaust Gas Recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt.
Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .

Fig 1: Identifying Fuel Pump Fuse
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the Manifold Air Temperature (MAT) sensor connector.
Disconnect the air cleaner outlet hose from the throttle body.

Fig 2: Identifying Breather Tube To Camshaft Cover
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the Idle Air Control (IAC) valve connector.
Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
Disconnect the coolant hoses at the throttle body.

Fig 3: Identifying Coolant Hoses To Throttle Body
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
Remove the generator-to-intake manifold strap bracket bolts and strap.
Remove the fuel rail as an assembly. Refer to FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION .
Remove the generator-to-intake manifold support bracket bolts.
Remove the generator-to-intake manifold support bracket.
Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
Remove the intake manifold support bracket.

Fig 4: Identifying Intake Manifold Support Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Remove the intake manifold retaining bolt and nuts in the sequence shown.
Remove the intake manifold.
Remove the intake manifold gasket.
Clean the sealing surfaces of the intake manifold and the cylinder head.

Fig 5: Identifying Intake Manifold Retaining Bolt And Nuts In Sequence (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.