Intake Manifold Removal and Installation: Installation

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Install the intake manifold gasket.
Install the intake manifold.
Install the intake manifold retaining bolt and nuts in the sequence shown in illustration.
Tighten

Tighten the intake manifold retaining bolt and nuts to 22 N.m (16 lb-ft).
Install the generator-to-intake manifold strap bracket and bolts.
Tighten

Tighten the generator-to-intake manifold strap bracket bolts to 22 N.m (16 lb-ft).

Fig 1: Installing Intake Manifold Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the intake manifold support bracket.
Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten

Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 N.m (18 lb-ft).
Install the intake manifold support bracket lower bolt to the engine block.
Tighten

Tighten the intake manifold support bracket lower bolt to the engine block to 25 N.m (18 lb-ft).
Install the generator-to-intake manifold support bracket and bolts.
Tighten

Tighten the generator-to-intake manifold support bracket bolts to 37 N.m (27 lb-ft).

Fig 2: Installing Generator-To-Intake Manifold Support Bracket And Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the fuel rail and injector cover as an assembly. Refer to "FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION :".
Install the throttle cable bracket.
Install the throttle cable bracket bolts.
Tighten

Tighten the throttle cable bracket bolts to 8 N.m (71 lb-in).
Connect the throttle cable to the intake manifold and the throttle body.
Connect all of the necessary vacuum lines that were previously disconnected.

Fig 3: Installing Throttle Cable Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Connect the MAP sensor connector.
Connect the coolant hoses to the throttle body.
Connect the IAC valve connector.
Connect the TPS connector.

Fig 4: Connecting TPS Connector
Courtesy of SUZUKI OF AMERICA CORP.
Connect the air cleaner outlet hose to the throttle body.
Connect the MAT sensor connector.
Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt.
Tighten

Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 N.m (44 lb-in).
Install the fuel pump fuse.
Connect the negative battery cable.
Refill the engine cooling system. Refer to "DRAINING AND REFILLING THE COOLING SYSTEM :".