Inspection Procedure

Fig 1: Identifying Upper Intake Manifold Parts (1 Of 3)

Courtesy of SUZUKI OF AMERICA CORP.

1. 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: Identifying Upper Intake Manifold Parts (2 Of 3)

     Courtesy of SUZUKI OF AMERICA CORP.
2. 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: Identifying Upper Intake Manifold Parts (3 Of 3)

     Courtesy of SUZUKI OF AMERICA CORP.
3. 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: Checking Upper Intake Manifold Sealing Surface For Warpage

     Courtesy of SUZUKI OF AMERICA CORP.
4. 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 gauge between the upper intake manifold and the straight edge. An upper intake manifold with warpage in excess of 0.05 mm (0.020 in) must be replaced.
5. Repair or replace the upper intake manifold as necessary.

Fig 1: Identifying Lower Intake Manifold (1 Of 2)

Courtesy of SUZUKI OF AMERICA CORP.

1. 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: Identifying Lower Intake Manifold (2 Of 2)

     Courtesy of SUZUKI OF AMERICA CORP.
2. 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: Checking Lower Intake Manifold Sealing Surfaces For Warpage

     Courtesy of SUZUKI OF AMERICA CORP.
3. Inspect the lower intake manifold sealing surfaces for warpage.
   1. Locate a straight edge across the lower intake manifold sealing surfaces.
   2. Insert a feeler gauge 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.
4. Repair or replace the lower intake manifold as necessary.

Reference: INTAKE MANIFOLD ASSEMBLE .