Removal & Installation (Vitara)
WARNING: This page is about a different car, the 2002 Suzuki XL-7, 2002 Suzuki Vitara, 2002 Suzuki Grand Vitara, 2002 Suzuki Esteem, and 2002 Suzuki Aerio. However, it is still accessible from the selected car via links, so may be relevant.
- Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Relieve cooling system pressure and drain engine coolant so level is below throttle body. Remove air intake hose. Disconnect following electric lead wires: EGR valve, ground wires from intake manifold, MAP sensor, engine coolant temperature sensor, injector lead wires at the coupler, EVAP canister purge valve, throttle position sensor and idle air control valve. Disconnect accelerator cable and kickdown cable (A/T) from throttle body. See Figure .
- Disconnect the following hoses: brake booster hose form intake manifold, canister purge hose from EVAP canister purge valve, engine coolant hose (outlet side) from throttle body, radiator inlet hose from thermostat cap, PCV hoses from intake manifold and throttle body, fuel feed hose and return hose from each pipe and vacuum hose from intake manifold.
- Remove generator adjust arm and intake manifold stiffeners. Remove intake manifold with throttle body from cylinder head and then remove its gasket. To install, reverse removal procedures. Use NEW intake manifold gasket. Tighten nuts to specification. See TORQUE SPECIFICATIONS . After installing accelerator cable, ensure cable has correct free play. See ON-VEHICLE ADJUSTMENTS article. Refill coolant.