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Intake Collector And Intake Manifold Removal And Installation: Removal

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove electric throttle body assembly referring to ELECTRIC THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION .
  2. Disconnect water hose (1) from heater outlet pipe.
  3. Remove heater outlet pipe bolts (2).
    Fig 1: Identifying Heater Outlet Pipe Bolts
    G04807321Courtesy of SUZUKI OF AMERICA CORP.
  4. Disconnect MAP sensor connector (1) and fuel injector harness connector (2).
  5. Remove harness clamp bracket (right side) (3) from intake collector.
  6. Disconnect vacuum hose (4) of EVAP canister purge valve from intake collector.
    Fig 2: Identifying MAP Sensor Connector & Fuel Injector Harness Connector
    G04807322Courtesy of SUZUKI OF AMERICA CORP.
  7. Disconnect EVAP canister purge valve connector (1) and ground terminals (2).
  8. Remove harness clamp bracket (left side) (3) from intake collector.
    Fig 3: Identifying EVAP Canister Purge Valve Connector
    G04807323Courtesy of SUZUKI OF AMERICA CORP.
  9. Disconnect EGR valve assembly connector (1), EGR pipe (2) and PCV hose (3).
  10. Detach intake collector (4) from intake manifold, and then disconnect water hose (5).
    Fig 4: Identifying EGR Valve Assembly Connector
    G04807324Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove EGR valve assembly (1) and PCV pipe (2) from intake collector, if necessary.
    Fig 5: Identifying EGR Valve Assembly & PCV Pipe
    G04807325Courtesy of SUZUKI OF AMERICA CORP.
  12. Disconnect brake booster hose (2) and vacuum tank hose (4) from intake manifold (1) then EVAP canister purge valve hose (3) from fuel No. 2 pipe (5).
    Fig 6: Identifying EVAP Canister Purge Valve Hose
    G04807326Courtesy of SUZUKI OF AMERICA CORP.
  13. Disconnect fuel feed hose (1) and fuel return hose (2).
  14. Remove fuel No. 2 pipe bolts (3).
    Fig 7: Identifying Fuel Feed Hose & Fuel Return Hose
    G04807327Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove intake manifold bolts (8 pcs.) and nuts (4 pcs.).
    Fig 8: Identifying Intake Manifold Bolts & Nuts
    G04807328Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove intake manifold.
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