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Intake Manifold Removal

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to DRAINING AND REFILLING THE COOLING SYSTEM .
    Fig 1: Removing/Installing Engine Beautification Cover Retaining Nuts
    G04718858Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove the engine beautification cover retaining nut and engine beautification cover.
  6. Remove the air filter snorkel.
    Fig 2: Identifying Air Filter Snorkel
    G04718859Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the VIS vacuum tank.
    Fig 3: Removing/Installing VIS Vacuum Tank Bolts
    G04718818Courtesy of SUZUKI OF AMERICA CORP.
  8. Disconnect the fuel pressure regulator vacuum hose.
  9. Disconnect the fuel line.
    Fig 4: Identifying Fuel Pressure Regulator Vacuum Hose And Fuel Line
    G04718861Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove the breather hose.
  11. Remove the PCV vacuum hose.
    Fig 5: Identifying Breather Hose And PCV Hose
    G04718862Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the air filter outlet hose. Refer to Air Intake System Location .
  13. Remove the throttle body assembly. Refer to Throttle Body Assembly Removal .
    Fig 6: Removing/Installing Throttle Body Retaining Bolts
    G04718853Courtesy of SUZUKI OF AMERICA CORP.
  14. Disconnect the charcoal canister purge solenoid connector and hose. Refer to Air Intake System Location .
  15. Disconnect the Oxygen Sensor (O2S) connector. Refer to OXYGEN SENSOR (O2S) REMOVAL .
  16. Disconnect the Manifold Absolute Pressure (MAP) sensor connector. Refer to MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL .
  17. Disconnect the Crankshaft Position (CKP) sensor connector. Refer to CRANKSHAFT POSITION (CKP) SENSOR REMOVAL .
    Fig 7: Identifying Oxygen Sensor Wiring Harness Connector
    G04718793Courtesy of SUZUKI OF AMERICA CORP.
  18. Disconnect the Exhaust Gas Recirculation (EGR) solenoid connector. Refer to EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL .
  19. Disconnect the Camshaft Position (CMP) sensor connector. Refer to CAMSHAFT POSITION (CMP) SENSOR REMOVAL .
  20. Remove the Intake Air Temperature (IAT) sensor. Refer to INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL .
  21. Disconnect the ignition coil connector. Refer to IGNITION COIL REMOVAL .
  22. Remove the vacuum hose on the brake booster.
    Fig 8: Removing Vacuum Hose On Brake Booster
    G04718865Courtesy of SUZUKI OF AMERICA CORP.
  23. Remove the EGR pipe from the intake manifold.
  24. Remove the engine coolant temperature sensor.
    Fig 9: Removing/Installing Engine Coolant Temperature Sensor And EGR Pipe Retaining Bolts
    G04718806Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove the wiring harness from the support bracket on the cylinder block.
    Fig 10: Identifying Wiring Harness
    G04718829Courtesy of SUZUKI OF AMERICA CORP.
  26. Remove the intake manifold retaining nuts/bolts and the intake manifold.
  27. Remove the bolts on the intake manifold support bracket.
  28. Remove the intake manifold gaskets.
  29. Clean the contact surfaces between intake manifold and the cylinder head.
    NOTE: Remove the fuel rail after removing the intake manifold.
    Fig 11: Removing/Installing Intake Manifold Retaining Nuts And Bolts
    G04718868Courtesy of SUZUKI OF AMERICA CORP.
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