Inspection 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: Inspecting Upper Intake Manifold

Courtesy of SUZUKI OF AMERICA CORP.

Inspect the upper intake manifold for the following conditions:
- Damage, debris or restrictions to the PCV system hose port (1)
- Damage, debris or restrictions to the EVAP purge solenoid port (2)
- Damage to the intake manifold bolt bosses (3)
- Damage to the EVAP purge solenoid mounting boss (4)
- Damage, debris or restrictions to the brake vacuum booster hose port (5)
- Damage or corrosion to the intake manifold expansion plugs (6)
- Damage to the engine coolant air bleed pipe bracket mounting boss (7)
  
  Fig 2: Inspecting Upper Intake Manifold
  Courtesy of SUZUKI OF AMERICA CORP.
Inspect the upper intake manifold for the following conditions:
- Damage to the threads and boss for the fuel injector sight shield ball stud (1)
- Damage, debris or restrictions within the intake manifold passages (2)
- Damage to the engine coolant air bleed pipe bracket mounting boss (3)
- Damage to the intake manifold bolt bosses (4)
- Damage or corrosion to the intake manifold expansion plug (5)
- Damage to the throttle body bolt holes (6)
  
  Fig 3: Inspecting Upper Intake Manifold
  Courtesy of SUZUKI OF AMERICA CORP.
Inspect the upper intake manifold for the following conditions:
- Gouges or damage to the upper intake manifold sealing surfaces (1)
- Damage to the gasket sealing surface (2) for the throttle body
  
  Fig 4: Inspecting Upper Intake Manifold Sealing Surface For Warpage
  Courtesy of SUZUKI OF AMERICA CORP.
Inspect the upper intake manifold sealing surface for warpage.
1. Locate a straight edge across the upper-to-lower intake manifold sealing surface.
2. Insert a feeler gage between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.50 mm (0.020 in) must be replaced.
Repair or replace the upper intake manifold as necessary.

Fig 1: Inspecting Lower Intake Manifold

Courtesy of SUZUKI OF AMERICA CORP.

Inspect the lower intake manifold for the following conditions:
- Damage, debris or restrictions to the lower intake manifold ports
- Damage to the fuel rail mounting bolt holes
- Damage to the fuel rail
  
  Fig 2: Inspecting Lower Intake Manifold
  Courtesy of SUZUKI OF AMERICA CORP.
Inspect the lower intake manifold for the following conditions:
- Gouges or damage to the intake manifold sealing surfaces
- Damage to the lower intake manifold bolt bosses
- Damage to the fuel injector ports
  
  Fig 3: Inspecting Lower Intake Manifold Sealing Surfaces For Warpage
  Courtesy of SUZUKI OF AMERICA CORP.
Inspect the lower intake manifold sealing surfaces for warpage.
- Locate a straight edge across the lower intake manifold sealing surfaces.
- Insert a feeler gage between the lower intake manifold and the straight edge. A lower intake manifold with warpage in excess of 0.5 mm (0.020 in) must be replaced.
Repair or replace the lower intake manifold as necessary.
Reference: INTAKE MANIFOLD ASSEMBLE