Suzuki Esteem, Swift 1994-02

Intake Manifold

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Removal & Installation





Click image to see an enlarged view

Fig. Intake manifold and related components-1.3L engine


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant from the vehicle.
    WARNING
    To help avoid the danger of being burned, do not remove the drain plug and the radiator cap while the engine is still hot. Scalding fluid and steam can be blown out under pressure if the plug and cap are taken off too soon.

  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     

  8.  
  9. Disconnect the following electrical wires:

    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Idle Speed Control (ISC) actuator
     
    Ground wires from the intake manifold
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Tank pressure control solenoid vacuum valve, if equipped
     
    Manifold Absolute Pressure (MAP) sensor
     

  10.  
  11. Remove or disconnect the following:

    Fuel return and feed hoses from the fuel pipes
     
    Coolant hoses from the throttle body and the intake manifold
     

  12.  
  13. Disconnect the following vacuum hoses:

    Canister purge hose from the intake manifold
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold
     
    Brake booster hose from the intake manifold
     
    Positive Crankcase Ventilation (PCV) hose from the PCV valve
     
    Accelerator cable from the throttle body
     

  14.  
  15. Remove or disconnect the following:

    Intake manifold attaching nuts and bolts
     
    Intake manifold and throttle body
     

  16.  

To install:

  1. Before installing the gasket, make sure that the mating surfaces of the intake manifold and the cylinder head are clean and undamaged.
  2.  
  3. Install or connect the following:

    New intake manifold gasket on the cylinder head
     
    Intake manifold and throttle body on the cylinder head
     
    Intake manifold mounting nuts and bolts. Tighten the nuts and bolts to 13-20 ft. lbs. (18-28 Nm). Be sure that the clamps are properly installed on the lower intake manifold bolts.
     
    Remaining components in the reverse order of removal
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for fuel and cooling system leaks.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-1.6L engine

  10.  

1.3L And 1.6L Engines


Click image to see an enlarged view

Fig. Intake manifold and related components-1.3L engine


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant from the vehicle.
    WARNING
    To help avoid the danger of being burned, do not remove the drain plug and the radiator cap while the engine is still hot. Scalding fluid and steam can be blown out under pressure if the plug and cap are taken off too soon.

  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     

  8.  
  9. Disconnect the following electrical wires:

    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Idle Speed Control (ISC) actuator
     
    Ground wires from the intake manifold
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Tank pressure control solenoid vacuum valve, if equipped
     
    Manifold Absolute Pressure (MAP) sensor
     

  10.  
  11. Remove or disconnect the following:

    Fuel return and feed hoses from the fuel pipes
     
    Coolant hoses from the throttle body and the intake manifold
     

  12.  
  13. Disconnect the following vacuum hoses:

    Canister purge hose from the intake manifold
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold
     
    Brake booster hose from the intake manifold
     
    Positive Crankcase Ventilation (PCV) hose from the PCV valve
     
    Accelerator cable from the throttle body
     

  14.  
  15. Remove or disconnect the following:

    Intake manifold attaching nuts and bolts
     
    Intake manifold and throttle body
     

  16.  

To install:

  1. Before installing the gasket, make sure that the mating surfaces of the intake manifold and the cylinder head are clean and undamaged.
  2.  
  3. Install or connect the following:

    New intake manifold gasket on the cylinder head
     
    Intake manifold and throttle body on the cylinder head
     
    Intake manifold mounting nuts and bolts. Tighten the nuts and bolts to 13-20 ft. lbs. (18-28 Nm). Be sure that the clamps are properly installed on the lower intake manifold bolts.
     
    Remaining components in the reverse order of removal
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for fuel and cooling system leaks.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-1.6L engine

  10.  

1.8L Engine

CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant from the vehicle.
    WARNING
    To help avoid the danger of being burned, do not remove the drain plug and the radiator cap while the engine is still hot. Scalding fluid and steam can be blown out under pressure if the plug and cap are taken off too soon.

  6.  
  7. Remove the throttle body assembly from intake manifold.
  8.  
  9. Remove accelerator cable from bracket.
  10.  
  11. Disconnect the following electric lead wires:

    IAC sensor connector
     
    EGR valve connector
     
    EVAP canister purge valve connector
     
    MDP sensor connector
     

  12.  
  13. Disconnect the following hoses:

    Brake booster hose from intake manifold
     
    PCV hose from PCV valve
     
    Fuel pressure regulator vacuum hose from intake manifold
     
    Vacuum hose from EVAP canister purge valve
     

  14.  
  15. Remove intake manifold front stiffener and rear stiffener.
  16.  
  17. Remove EGR pipe.
  18.  
  19. Disconnect coolant pipe from intake manifold.
  20.  
  21. Remove intake manifold from cylinder head, and then its gasket.

    Click image to see an enlarged view

    Fig. Intake manifold gasket (1), intake manifold (2) and fasteners (a)-1.8L engine

  22.  

To install:

  1. Install new intake manifold gasket to cylinder head.
  2.  
  3. Install intake manifold. Tighten bolts and nuts to 17 ft. lbs. (23 Nm).
  4.  
  5. Connect coolant pipe to intake manifold.
  6.  
  7. Install EGR pipe.
  8.  
  9. Install intake manifold front stiffener and rear stiffener. Tighten the front stiffener bolts to 18 ft. lbs. (25 Nm). Tighten the rear stiffener bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Connect the following hoses:

    Brake booster hose to intake manifold
     
    PCV hose to PCV valve
     
    Fuel pressure regulator vacuum hose to intake manifold
     
    Vacuum hose to EVAP canister purge valve
     

  12.  
  13. Connect the following electric lead wires:

    IAC sensor
     
    EGR valve
     
    EVAP canister purge valve
     
    MDP sensor
     

  14.  
  15. Install accelerator cable to bracket.
  16.  
  17. Install the throttle body assembly onto the intake manifold with a new gasket and tighten bolts and nuts.
  18.  
  19. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  20.  
  21. Refill cooling system.
  22.  
  23. Connect negative cable at battery.
  24.  
  25. Finally, start engine and check for engine coolant leaks.
  26.  

 
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