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Intake Manifold Removal and Installation: Installation

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2008 Suzuki Reno, 2008 Suzuki Forenza, 2007 Suzuki Reno, 2007 Suzuki Forenza, and 2006 Suzuki Reno. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the intake manifold gasket.
  2. Install the intake manifold.
  3. Install the intake manifold retaining bolt and nuts in the sequence shown.

    Tighten: 

    Tighten the intake manifold retaining bolt and nuts to 22 N.m (16 lb-ft).

  4. 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: Identifying Intake Manifold Retaining Bolt And Nuts In Sequence (2 Of 2)
    G04716443Courtesy of SUZUKI OF AMERICA CORP.
  5. Install the intake manifold support bracket.
  6. 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).

  7. 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).

  8. 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: Identifying Intake Manifold Support Bracket
    G04716441Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the fuel rail and injector cover as an assembly. Refer to FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION .
  10. Connect all of the necessary vacuum lines that were previously disconnected.
  11. Connect the MAP sensor connector.
  12. Connect the coolant hoses to the throttle body.
  13. Connect the ETC connector.
    Fig 3: Identifying Coolant Hoses To Throttle Body
    G04716445Courtesy of SUZUKI OF AMERICA CORP.
  14. Connect the air cleaner outlet hose to the throttle body.
  15. Connect the MAT sensor connector.
  16. 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).

  17. Install the fuel pump fuse.
  18. Connect the negative battery cable.
  19. Refill the engine cooling system. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
    Fig 4: Identifying Negative Battery Cable
    G04716406Courtesy of SUZUKI OF AMERICA CORP.
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