Suzuki Forenza, Reno 2003-06

Intake Manifold

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Removal & Installation




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. Remove the fuel pump fuse.
  4.  
  5. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain the engine coolant.
  10.  
  11. Remove or disconnect the following:

    Charcoal Canister Purge (CCP) and Exhaust Gas Recirculation (EGR) solenoid from the intake manifold
     
    Bracket bolt
     
    Manifold Air Temperature (MAT) sensor connector
     
    Air cleaner outlet hose from throttle body
     
    Idle Air Control (IAC) valve connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Coolant hoses at the throttle body
     
    All necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at intake manifold
     
    Alternator-to-intake manifold strap bracket bolts and strap
     
    Fuel rail as an assembly
     
    Alternator-to-intake manifold support bracket bolts
     
    Alternator-to-intake manifold support bracket
     
    Intake manifold support bracket bolt at the engine block and the intake manifold
     
    Intake manifold support bracket
     
    Intake manifold retaining bolt and nuts in the sequence shown
     
    Intake manifold and intake manifold gasket
     

  12.  
  13. Clean the sealing surfaces of the intake manifold and the cylinder head.

    Click image to see an enlarged view

    Fig. Intake manifold bolt loosening sequence-2.0L engine

  14.  

To install:

  1. Install or connect the following:

    New intake manifold gasket
     
    Intake manifold, intake manifold retaining bolt and nuts and tighten, in sequence, to 16 ft. lbs. (22 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-2.0L engine

     
    Alternator-to-intake manifold strap bracket and bolts. Tighten the alternator-to-intake manifold strap bracket bolts to 16 ft. lbs. (22 Nm).
     
    Intake manifold support bracket
     
    Intake manifold support bracket upper bolts to the intake manifold and tighten to 18 ft. lbs. (25 Nm)
     
    Intake manifold support bracket lower bolt to the engine block and tighten to 18 ft. lbs. (25 Nm)
     
    Alternator-to-intake manifold support bracket and bolts and tighten to 27 ft. lbs. (37 Nm)
     
    Fuel rail and injector cover as an assembly
     
    All of the necessary vacuum lines that were previously disconnected
     
    MAP sensor connector
     
    Coolant hoses to the throttle body
     
    ETC connector
     
    Air cleaner outlet hose to the throttle body
     
    MAT sensor connector
     
    CCP and EGR solenoid at the intake manifold and tighten the bracket bolt to 44 inch lbs. (5 Nm)
     
    Fuel pump fuse
     

  2.  
  3. Check to ensure that all removed parts are back in place.
  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.
  10.  

 
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