Throttle Body, Intake Manifold Removal & Installation: Removal

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Relieve fuel pressure according to RELIEVING FUEL PRESSURE .
Disconnect negative cable at battery.
Drain coolant.
WARNING: To help avoid danger of being burned, do not remove drain plug (1) and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

Fig 1: Identifying Radiator Drain Plug
Courtesy of SUZUKI OF AMERICA CORP.
Remove air cleaner outlet hose
Disconnect the following electric lead wires:
- EGR valve coupler
- IAC valve coupler
- TP sensor coupler
- EVAP canister purge valve coupler
- Ground terminal from intake manifold
- MAP sensor
Fig 2: Identifying MAP Sensor, IAC Valve Coupler, TP Sensor Coupler & Ground Terminal
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect accelerator cable and A/T throttle cable (For A/T vehicle) from throttle body.
Disconnect the following hoses:
- Brake booster hose from intake manifold
- PCV hose from intake manifold
- Fuel pressure regulator vacuum hose from intake manifold
- Canister purge hose from EVAP canister purge valve
- Vacuum hose from intake manifold
- Water hoses from throttle body and water bypass pipe
- Breather hose from throttle body
- Fuel feed hose and return hose from each pipe
Fig 3: Identifying Engine Hoses
Courtesy of SUZUKI OF AMERICA CORP.
Remove fuel delivery pipe with fuel injectors from cylinder head.
Remove intake manifold front stiffener and rear stiffener.
Detach water pipe from intake manifold.
Remove intake manifold (1) from cylinder head, and then its gasket (2).

Fig 4: Removing Intake Manifold & Gasket
Courtesy of SUZUKI OF AMERICA CORP.