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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> 2.7L V6 >> Repair Instructions >> Throttle Body & Intake Manifold Removal & Installation >> Installation

Throttle Body & Intake Manifold Removal & Installation: Installation

  1. Install new intake manifold gaskets (1) to cylinder heads.
    Fig 1: Installing Intake Manifold Gaskets
    G02263899Courtesy of SUZUKI OF AMERICA CORP.
  2. Install intake manifold (1), and tighten bolts (2) and nuts (3).
    Fig 2: Installing Intake Manifold
    G02263900Courtesy of SUZUKI OF AMERICA CORP.
  3. Install throttle body (2) to intake collector (1) with new throttle body gasket.
    Fig 3: Installing Throttle Body To Intake Collector
    G02263901Courtesy of SUZUKI OF AMERICA CORP.
  4. Install IAC valve, EGR valve (1), EVAP canister purge valve (2), MAP sensor and each hoses to intake collector and throttle body if removed.
    NOTE: Use new gasket when installing IAC valve and EGR valve.
    Fig 4: Installing Components & Hoses To Intake Collector & Throttle Body
    G02263902Courtesy of SUZUKI OF AMERICA CORP.
  5. Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
  6. Connect hoses of heater (1), EVAP canister (4), fuel feed (2) and fuel return (3).
    Fig 5: Connecting Hoses
    G02263903Courtesy of SUZUKI OF AMERICA CORP.
  7. Install EGR pipe (3) with new gaskets.
  8. Connect hoses of EVAP canister purge valve (4) and heater (5).
  9. Connect hoses of PCV (6), breather (8) and water (7).
  10. Connect couplers of manifold absolute pressure (MAP) sensor, EVAP canister purge valve (1), EGR valve (2) and earth terminal (9).

    Fix wire harness with clamps.

    Fig 6: Connecting Couplers & Hoses
    G02263904Courtesy of SUZUKI OF AMERICA CORP.
  11. Install clamp bracket (4) to intake collector.
  12. Connect earth terminal (3) to intake collector.
  13. Connect couplers of TP sensor (1) and IAC valve (2).
    Fig 7: Installing Clamp Bracket To Intake Collector
    G02263905Courtesy of SUZUKI OF AMERICA CORP.
  14. Connect brake booster hose (2), fuel pressure regulator vacuum hose (4) and intake control valve hose (3) to intake manifold.
  15. Connect injector wire (1) coupler.
    Fig 8: Connecting Hoses To Intake Manifold
    G02263906Courtesy of SUZUKI OF AMERICA CORP.
  16. Connect water hoses (2) to throttle body.
  17. Connect accelerator cable (1) to throttle body.
    Fig 9: Connecting Accelerator Cable To Throttle Body
    G02263907Courtesy of SUZUKI OF AMERICA CORP.
  18. Install surge tank pipe (2) and intake control valve (3) to intake manifold with new gaskets and intake air pipe (1) to throttle body.
    Fig 10: Installing Surge Tank Pipe & Intake Control Valve
    G02263908Courtesy of SUZUKI OF AMERICA CORP.
  19. Install surge tank cover (1).
    Fig 11: Installing Surge Tank Cover
    G02263909Courtesy of SUZUKI OF AMERICA CORP.
  20. Install air cleaner upper case.
  21. Connect coupler to intake air temp. sensor and MAF sensor.
  22. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification.

    Tightening torque 

    Strut tower bar mounting bolts (a):  50 N.m (5.0 kg-m, 36.5 lb-ft)

    Fig 12: Installing Strut Tower Bar
    G02263910Courtesy of SUZUKI OF AMERICA CORP.
  23. Install fuse/relay box.
  24. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  25. Refill cooling system referring to COOLING SYSTEM FLUSH & REFILL .
  26. Connect negative cable (-) at battery.
  27. Upon completion of installation, verify that there is no fuel leakage at each connection according to FUEL LEAKAGE CHECK PROCEDURE .
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