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Removal (Grand Vitara & XL-7)

WARNING: This page is about a different car, the 2003 Suzuki XL-7, 2003 Suzuki Vitara, 2003 Suzuki Grand Vitara, and 2003 Suzuki Aerio. 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  .
    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. See Figure .
    WARNING: To help avoid danger of being burned, do not remove drain plug 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.
  4. Detach fuse/relay box and remove strut tower bar.
  5. Disconnect coupler from IAT sensor.
  6. Remove surge tank cover (1). See Figure .
  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. See Figure .
  8. Disconnect accelerator cable (1) and A/T throttle cable (for A/T model) (2) from throttle body. See Figure .
  9. Disconnect water hose (3) from throttle body. See Figure .
  10. Disconnect injector wire (1) coupler. See Figure .
  11. Disconnect brake booster hose (2) from intake manifold. See Figure .
  12. Disconnect couplers of TP sensor (1), MAF sensor (2) and IAC valve (3). See Figure .
  13. Disconnect earth terminal (4) from intake collector. See Figure .
  14. Remove clamp bracket (5) from intake collector. See Figure .
  15. Disconnect couplers from manifold absolute pressure (MAP) sensor, EVAP canister purge valve (1) and EGR valve (2). See Figure .
  16. Disconnect PCV hose (6) from cylinder head cover. See Figure .
  17. Disconnect breather hoses (8) from throttle body or cylinder head cover. See Figure .
  18. Disconnect EVAP canister purge valve hose (4), heater hose (5) and water hose (7). See Figure .
  19. Remove EGR pipe (3). See Figure .
  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). See Figure .
  21. Remove throttle body (1) and intake collector (2) from intake manifold (3). See Figure .
  22. Disconnect IAC valve hose (1) and EVAP canister purge valve hose from intake collector. See Figure .
  23. Remove throttle body (2) from intake collector. See Figure .
  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 (1). See Figure .
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