Suzuki Vitara, Grand Vitara, XL7 2000-06

Intake Manifold

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Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake pipe
     
    Accelerator cable and bracket
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector and hoses
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant temperature gauge sender connector
     
    A/C coolant temperature switch connector, if equipped
     
    Evaporative Emission (EVAP) canister purge valve connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) temperature sensor connector
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    EGR vacuum lines
     
    Fuel injector connectors
     
    Intake manifold ground cable
     
    Transmission vacuum line, if equipped
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the nuts to 17 ft. lbs. (23 Nm).
     
    Intake manifold brackets. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Alternator bracket. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    MAP sensor vacuum line
     
    Brake booster vacuum line
     
    Transmission vacuum line, if equipped
     
    Intake manifold ground cable
     
    Fuel injector connectors
     
    EGR vacuum lines
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR temperature sensor connector
     
    EVAP canister purge valve connector and vacuum line
     
    A/C coolant temperature switch connector, if equipped
     
    Coolant temperature gauge sender connector
     
    ECT sensor connector
     
    IAC valve connector and hoses
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Accelerator cable and bracket
     
    Air intake pipe
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake pipe
     
    Accelerator cable and bracket
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector and hoses
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant temperature gauge sender connector
     
    A/C coolant temperature switch connector, if equipped
     
    Evaporative Emission (EVAP) canister purge valve connector and vacuum line
     
    Exhaust Gas Recirculation (EGR) temperature sensor connector
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    EGR vacuum lines
     
    Fuel injector connectors
     
    Intake manifold ground cable
     
    Transmission vacuum line, if equipped
     
    Brake booster vacuum line
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Fuel lines
     
    Upper radiator hose
     
    Coolant bypass hose
     
    Alternator bracket
     
    Intake manifold brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the nuts to 17 ft. lbs. (23 Nm).
     
    Intake manifold brackets. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Alternator bracket. Tighten the fasteners to 36 ft. lbs. (50 Nm).
     
    Coolant bypass hose
     
    Upper radiator hose
     
    Fuel lines
     
    MAP sensor vacuum line
     
    Brake booster vacuum line
     
    Transmission vacuum line, if equipped
     
    Intake manifold ground cable
     
    Fuel injector connectors
     
    EGR vacuum lines
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR temperature sensor connector
     
    EVAP canister purge valve connector and vacuum line
     
    A/C coolant temperature switch connector, if equipped
     
    Coolant temperature gauge sender connector
     
    ECT sensor connector
     
    IAC valve connector and hoses
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Accelerator cable and bracket
     
    Air intake pipe
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

1.8L And 2.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emissions (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Fuel pressure regulator vacuum hose
     
    Intake manifold vacuum hose
     
    Throttle body coolant hoses
     
    Water bypass pipe
     
    Fuel lines
     
    Fuel supply manifold with injectors attached
     
    Intake manifold support brackets
     
    Intake manifold water pipe
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the fasteners to 17 ft. lbs. (23 Nm).
     
    Intake manifold water pipe
     
    Intake manifold front support bracket. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Intake manifold rear support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel supply manifold with injectors attached
     
    Fuel lines
     
    Water bypass pipe
     
    Throttle body coolant hoses
     
    Intake manifold vacuum hose
     
    Fuel pressure regulator vacuum hose
     
    PCV valve and hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    MAP sensor connector
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Evaporative Emissions (EVAP) canister purge valve connector and hose
     
    Intake manifold ground cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Fuel pressure regulator vacuum hose
     
    Intake manifold vacuum hose
     
    Throttle body coolant hoses
     
    Water bypass pipe
     
    Fuel lines
     
    Fuel supply manifold with injectors attached
     
    Intake manifold support brackets
     
    Intake manifold water pipe
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Tighten the fasteners to 17 ft. lbs. (23 Nm).
     
    Intake manifold water pipe
     
    Intake manifold front support bracket. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Intake manifold rear support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel supply manifold with injectors attached
     
    Fuel lines
     
    Water bypass pipe
     
    Throttle body coolant hoses
     
    Intake manifold vacuum hose
     
    Fuel pressure regulator vacuum hose
     
    PCV valve and hose
     
    Brake booster vacuum hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    MAP sensor connector
     
    Intake manifold ground cable
     
    EVAP canister purge valve connector and hose
     
    TP sensor connector
     
    IAC valve connector
     
    EGR valve connector
     
    Air intake tube
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar
     
    Intake Air Temperature (IAT) sensor connector
     
    Surge tank cover
     
    Air intake assembly
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Throttle body coolant hoses
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Intake manifold ground cables
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) canister purge valve connector and hoses
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Heater hoses
     
    EGR pipe
     
    Fuel lines
     
    Throttle body and intake collector
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with new gaskets. Tighten the fasteners to 16 ft. lbs. (23 Nm).
     
    Throttle body and intake collector with new gaskets. Tighten the fasteners to 102 inch lbs. (12 Nm).
     
    Fuel lines
     
    EGR pipe
     
    Heater hoses
     
    PCV valve and hose
     
    EGR valve connector
     
    EVAP canister purge valve connector and hoses
     
    Brake booster vacuum hose
     
    Intake manifold ground cables
     
    IAC valve connector
     
    MAF sensor connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    Throttle body coolant hoses
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake assembly
     
    Surge tank cover
     
    IAT sensor connector
     
    Strut tower bar
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar
     
    Intake Air Temperature (IAT) sensor connector
     
    Surge tank cover
     
    Air intake assembly
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Throttle body coolant hoses
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Intake manifold ground cables
     
    Brake booster vacuum hose
     
    Evaporative Emissions (EVAP) canister purge valve connector and hoses
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Heater hoses
     
    EGR pipe
     
    Fuel lines
     
    Throttle body and intake collector
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold with new gaskets. Tighten the fasteners to 16 ft. lbs. (23 Nm).
     
    Throttle body and intake collector with new gaskets. Tighten the fasteners to 102 inch lbs. (12 Nm).
     
    Fuel lines
     
    EGR pipe
     
    Heater hoses
     
    PCV valve and hose
     
    EGR valve connector
     
    EVAP canister purge valve connector and hoses
     
    Brake booster vacuum hose
     
    Intake manifold ground cables
     
    IAC valve connector
     
    MAF sensor connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    Throttle body coolant hoses
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake assembly
     
    Surge tank cover
     
    IAT sensor connector
     
    Strut tower bar
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Throttle body assembly
     
    Water hose from heater outlet pipe
     
    Heater outlet pipe bolts
     
    MAP sensor connector
     
    Fuel injector harness connector
     
    Harness clamp bracket (right side) from intake collector
     
    Vacuum hose of EVAP canister purge valve from intake
     
    Canister purge valve connector and ground terminals
     
    Harness clamp bracket (left side) from intake collector
     
    EGR valve assembly connector
     
    EGR pipe
     
    PCV hose
     

  10.  
  11. Detach intake collector from intake manifold and then disconnect water hose.
  12.  
  13. Remove EGR valve assembly and PCV pipe from intake collector, if necessary.
  14.  
  15. Disconnect brake booster hose and vacuum tank hose from intake manifold then EVAP canister purge valve hose from fuel No.2 pipe.
  16.  
  17. Disconnect fuel feed hose and fuel return hose.
  18.  
  19. Remove fuel No.2 pipe bolt.
  20.  
  21. Remove intake manifold bolts and nuts.
  22.  
  23. Remove intake manifold.
  24.  

To install:

  1. Reverse removal procedure for installation noting the following.
    1. Use new intake manifold gaskets.
    2.  
    3. Use new intake collector gaskets, EGR valve gasket and EGR pipe gasket.
    4.  
    5. Check to ensure that all removed parts are back in place.
    6.  
    7. Reinstall any necessary parts which have not been reinstalled.
    8.  
    9. Refill cooling system.
    10.  

  2.  
  3. Connect the negative battery cable.
  4.  
  5. Upon completion of installation, verify that there is no fuel leakage at each connection.
  6.  

  1. Release fuel pressure in fuel feed line.
  2.  
  3. Disconnect negative cable at battery.
  4.  
  5. Drain coolant.
  6.  
  7. Detach fuse/relay box and remove strut tower bar.
  8.  
  9. Disconnect coupler from IAT sensor and MAF sensor.
  10.  
  11. Remove surge tank cover.
  12.  
  13. Remove air cleaner upper case, MAF sensor, intake air hose, intake air pipe and surge tank pipe as one component. Do not disassemble them, when removing and reinstalling.
  14.  
  15. Remove intake control valve.
  16.  
  17. Disconnect accelerator cable from throttle body.
  18.  
  19. Disconnect water hoses from throttle body.
  20.  
  21. Disconnect injector wire coupler.
  22.  
  23. Disconnect brake booster hose, fuel pressure regulator vacuum hose and intake control valve hose from intake manifold.

    Click image to see an enlarged view

    Fig. Intake manifold XL-7-2.7L

  24.  
  25. Disconnect couplers of TP sensor and IAC valve.
  26.  
  27. Disconnect earth terminal from intake collector.
  28.  
  29. Remove clamp bracket from intake collector.
  30.  
  31. Disconnect couplers from MAP sensor, EVAP canister purge valve, earth terminal and EGR valve.
  32.  
  33. Disconnect PCV hose from cylinder head cover.
  34.  
  35. Disconnect breather hoses from throttle body or cylinder head cover.
  36.  
  37. Disconnect EVAP canister purge valve hose, heater hose and water hose.
  38.  
  39. Remove EGR pipe and wire harness clamps.
  40.  
  41. Disconnect hoses of heater, EVAP canister purge, fuel feed and fuel return.
  42.  
  43. Remove throttle body and intake collector from intake manifold.
  44.  
  45. Disconnect hoses of PCV valve and EVAP canister purge valve from intake collector.
  46.  
  47. Remove throttle body from intake collector.
  48.  
  49. Remove IAC valve from throttle body.
  50.  
  51. Remove EGR valve and EVAP canister purge valve from intake collector.
  52.  
  53. Remove intake manifold bolts and nuts.
  54.  
  55. Remove IAC valve from throttle body.
  56.  
  57. Remove EGR valve and EVAP canister purge valve from intake collector.
  58.  
  59. Remove intake manifold bolts and nuts.
  60.  
  61. Remove intake manifold.
  62.  

To install:

Click image to see an enlarged view

Fig. Intake gaskets

  1. Install new intake manifold gaskets to cylinder heads.
  2.  
  3. Install intake manifold, and tighten bolts and nuts.
  4.  
  5. Install throttle body to intake collector with new throttle body gasket.
  6.  
  7. Install IAC valve, EGR valve, EVAP canister purge valve, MAP sensor and each hoses to intake collector and throttle body if removed.

    Click image to see an enlarged view

    Fig. Throttle body

  8.  
  9. Connect hoses of heater, EVAP canister, fuel feed and fuel return.
  10.  
  11. Install EGR pipe with new gaskets.
  12.  
  13. Connect hoses of EVAP canister purge valve and heater.
  14.  
  15. Connect hoses of PCV, breather and water.
  16.  
  17. Connect couplers of manifold absolute pressure (MAP) sensor, EVAP canister purge valve, EGR valve and earth terminal.
  18.  
  19. Fix wire harness with clamps.
  20.  
  21. Install clamp bracket to intake collector.
  22.  
  23. Connect earth terminal to intake collector.
  24.  
  25. Connect couplers of TP sensor and IAC valve.
  26.  
  27. Connect brake booster hose, fuel pressure regulator vacuum hose and intake control valve hose to intake manifold.
  28.  
  29. Connect injector wire coupler.
  30.  
  31. Connect water hoses to throttle body.
  32.  
  33. Connect accelerator cable to throttle body
  34.  
  35. Install surge tank pipe and intake control valve to intake manifold with new gaskets and intake air pipe to throttle body.
  36.  
  37. Install surge tank cover
  38.  
  39. Install air cleaner upper case.
  40.  
  41. Connect coupler to intake air temp. sensor and MAF sensor.
  42.  
  43. Install strut tower bar and tighten strut tower bar mounting bolts 36.5 ft. lbs. (50 Nm).
  44.  
  45. Install fuse/relay box.
  46.  
  47. Check to ensure that all removed parts are back in place.
  48.  
  49. Reinstall any necessary parts which have not been reinstalled.
  50.  
  51. Refill cooling system.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Check to make sure that there are no fuel leakages, performing the following steps.
  56.  
  57. Turn ON ignition switch for 3 seconds (to operate fuel pump), and then turn it OFF.
  58.  
  59. Repeat step 3 or 4 times, and apply fuel pressure to fuel line (till fuel pressure is felt by hand placed on fuel return hose).
  60.  
  61. In this state, check to see that there are no fuel leakages from any part of fuel system.
  62.  

 
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