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Installation Procedure

WARNING: This page is about a different car, the 2008 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Upper Intake Manifold And Gasket
G05465214Courtesy of SUZUKI OF AMERICA CORP.
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the upper intake manifold.
    CAUTION: Refer to FASTENER NOTICE .
  3. Apply threadlock to the bolt threads. Refer to SEALERS, ADHESIVES, AND LUBRICANTS .

    Tightening torque 

    Tighten the bolts to 25 N.m (18 lb ft)  .

  4. Install the upper intake manifold bolts.
  5. If the upper manifold was replaced, complete the following steps:
    1. Install the throttle body. Refer to THROTTLE BODY ASSEMBLY REPLACEMENT .
    2. Install the EVAP purge solenoid valve. Refer to EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE REPLACEMENT .
      Fig 2: Identifying Engine Harness Retaining Clips
      G05465215Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the engine harness retaining clips.
  7. Install the brake booster vacuum hose to the intake manifold.
  8. Install the brake booster vacuum hose to the intake manifold.
    Fig 3: Identifying Bleed Pipe Bolts And Hose Clamp
    G05465216Courtesy of SUZUKI OF AMERICA CORP.
  9. Position the bleed pipe.
  10. Install the bleed pipe hose clamp (2).
  11. Install the bleed pipe bolts (1).

    Tightening torque 

    Tighten the nut to 10 N.m (89 lb in)  .

  12. Connect the coolant hose bleed pipe.
    Fig 4: Identifying EVAP Canister Purge Line
    G05465217Courtesy of SUZUKI OF AMERICA CORP.
  13. Connect the EVAP canister purge line.
    Fig 5: Identifying PCV Line On Top Of Intake Manifold
    G05465218Courtesy of SUZUKI OF AMERICA CORP.
  14. Connect the PCV line to the top of the intake manifold.
    Fig 6: Identifying ETC Electrical Connector
    G05465219Courtesy of SUZUKI OF AMERICA CORP.
  15. Connect the ETC electrical connector.
  16. Install the air cleaner outlet duct.
    Fig 7: Identifying Fresh Air PCV Line On Air Cleaner Inlet Duct
    G05465220Courtesy of SUZUKI OF AMERICA CORP.
  17. Install the fresh air PCV line to the air cleaner inlet duct.
  18. Install the engine cover. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT .
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