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

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.
  1. Release fuel pressure in fuel feed line by referring to FUEL PRESSURE RELIEF PROCEDURE .
    CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.
  2. Disconnect negative (-) cable at battery.
  3. Drain coolant referring to COOLANT DRAINING .
  4. Detach fuse/relay box and remove strut tower bar.
  5. Disconnect coupler from IAT sensor.
  6. Remove surge tank cover (1).
    Fig 1: Removing Surge Tank Cover
    G02263867Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove air cleaner upper case, intake air hose, intake air pipe (1) and surge tank pipe (2) as one component. Do not disassemble them, when removing and reinstalling.
    Fig 2: Removing Air Cleaner Upper Case, Intake Air Hose, Intake Air Pipe & Surge Tank Pipe
    G02263868Courtesy of SUZUKI OF AMERICA CORP.
  8. Disconnect accelerator cable (1) and A/T throttle cable (for A/T model) (2) from throttle body.
  9. Disconnect water hose (3) from throttle body.
    Fig 3: Disconnecting Water Hose From Throttle Body
    G02263869Courtesy of SUZUKI OF AMERICA CORP.
  10. Disconnect injector wire (1) coupler.
  11. Disconnect brake booster hose (2) and fuel pressure regulator vacuum hose (3) from intake manifold.
    Fig 4: Disconnecting Brake Booster Hose & Fuel Pressure Regulator Vacuum Hose From Intake Manifold
    G02263870Courtesy of SUZUKI OF AMERICA CORP.
  12. Disconnect couplers of TP sensor (1), MAF sensor (2) and IAC valve (3).
  13. Disconnect earth terminal (4) from intake collector.
  14. Remove clamp bracket (5) from intake collector.
    Fig 5: Disconnect Couplers Of TP Sensor, MAF Sensor & IAC Valve, & Disconnecting Earth Terminal From Intake Collector, & Removing Clamp Bracket From Intake Collector
    G02263871Courtesy of SUZUKI OF AMERICA CORP.
  15. Disconnect couplers from MAP sensor, EVAP canister purge valve (1) and EGR valve (2).
  16. Disconnect PCV hose (6) from cylinder head cover.
  17. Disconnect breather hoses (8) from throttle body or cylinder head cover.
  18. Disconnect EVAP canister purge valve hose (4), heater hose (5) and water hose (7).
  19. Remove EGR pipe (3).
    Fig 6: Disconnecting Couplers, EVAP Canister Purge Valve, EGR Valve, PCV Hose, Breather Hoses, EVAP Canister Purge Valve Hose, Heater Hose & Water Hose, & Removing EGR Pipe
    G02263872Courtesy of SUZUKI OF AMERICA CORP.
  20. Disconnect heater hose (1), EVAP canister hose (4), tank pressure control solenoid valve hose (5), fuel feed hose (2) and fuel return hose (3).
    Fig 7: Disconnecting Heater Hose, EVAP Canister Hose, Tank Pressure Control Solenoid Valve Hose, Fuel Feed Hose & Fuel Return Hose
    G02263873Courtesy of SUZUKI OF AMERICA CORP.
  21. Remove throttle body (1) and intake collector (2) from intake manifold (3).
    Fig 8: Removing Throttle Body & Intake Collector From Intake Manifold
    G02263874Courtesy of SUZUKI OF AMERICA CORP.
  22. Disconnect IAC valve hose (1) and EVAP canister purge valve hose from intake collector.
  23. Remove throttle body (2) from intake collector.
    Fig 9: Disconnecting IAC Valve Hose & EVAP Canister Purge Valve Hose, & Removing Throttle Body
    G02263875Courtesy of SUZUKI OF AMERICA CORP.
  24. Remove IAC valve, EGR valve and EVAP canister purge valve from intake collector.
  25. Remove intake manifold bolts (8 pc.) and nuts (4 pc.).
  26. Remove intake manifold.
    Fig 10: Removing Intake Manifold
    G02263876Courtesy of SUZUKI OF AMERICA CORP.
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