Throttle Body & Intake Manifold Removal & Installation (H25 Engine): Installation

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install new intake manifold gaskets (1) to cylinder heads.

Fig 1: Installing Intake Manifold Gaskets
Courtesy of SUZUKI OF AMERICA CORP.
Install intake manifold and tighten bolts and nuts.

Fig 2: Installing Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.
Install throttle body (2) to intake collector (1) with new throttle body gasket.

Fig 3: Installing Throttle Body To Intake Collector
Courtesy of SUZUKI OF AMERICA CORP.
Install IAC valve (1), EGR valve (2), EVAP canister purge valve (3), MAP sensor, clamps 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
Courtesy of SUZUKI OF AMERICA CORP.
Install throttle body and intake collector assembly to intake manifold with new intake collector gaskets.
Connect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose (5), fuel feed hose (2) and fuel return hose (3).

Fig 5: Connecting Hoses
Courtesy of SUZUKI OF AMERICA CORP.
Install EGR pipe (3) with new gaskets.
Connect EVAP canister purge valve hose (4) and heater hose (5).
Connect PCV hose (6), breather hose (8) and water hose (7).
Connect couplers of MAP sensor, EVAP canister purge valve (1) and EGR valve (2). Fix wire harness with clamps.

Fig 6: Connecting Couplers & Hoses
Courtesy of SUZUKI OF AMERICA CORP.
Install clamp bracket (5) to intake collector.
Connect earth terminal (4) to intake collector.
Connect TP sensor coupler (1), MAF sensor coupler (2) and IAC valve coupler (3).

Fig 7: Installing Clamp Bracket To Intake Collector
Courtesy of SUZUKI OF AMERICA CORP.
Connect brake booster hose (2) and fuel pressure regulator vacuum hose (3) to intake manifold.
Connect injector wire (1) coupler.

Fig 8: Connecting Hoses To Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.
Connect water hoses (3) to throttle body.
Connect accelerator cable (1) and A/T throttle cable (for A/T model) (2) to throttle body, and adjust these cables referring to ACCELERATOR CABLE ADJUSTMENT and A/T THROTTLE CABLE ADJUSTMENT (H25 ENGINE WITH A/T ONLY) .

Fig 9: Connecting Accelerator Cable & A/T Throttle Cable (For A/T Model)
Courtesy of SUZUKI OF AMERICA CORP.
Install surge tank pipe (2) to intake manifold with new gaskets and intake air pipe (1) to throttle body.

Fig 10: Installing Surge Tank Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Install surge tank cover (1).

Fig 11: Installing Surge Tank Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install air cleaner upper case referring to AIR CLEANER ELEMENT REMOVAL & INSTALLATION .
Connect coupler to intake air temperature sensor.
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
Courtesy of SUZUKI OF AMERICA CORP.
Install fuse/relay box.
Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
Refill cooling system referring to COOLING SYSTEM FLUSH & REFILL .
Connect negative (-) cable at battery.
Upon completion of installation, verify that there is no fuel leakage at each connection according to procedure described in FUEL LEAKAGE CHECK PROCEDURE .