GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2009 🢒 XL-7 FWD 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 1828852 Size: SH
  1. Remove the engine cover. Refer to Fuel Injector Sight Shield Replacement .
  2. Remove the air cleaner outlet duct.
  3. Reposition the fresh air positive crankcase ventilation (PCV) line from the air cleaner inlet tube.

    4. Object Number: 1828897 Size: SH
  4. Disconnect the Electronic Throttle Control (ETC) electrical connector.

    5. Object Number: 1828339 Size: SH
  5. Disconnect the PCV line from the top of the intake manifold and reposition aside.

    6. Object Number: 1828971 Size: SH
  6. Disconnect the evaporative emissions (EVAP) canister purge line and reposition aside.

    7. Object Number: 1829016 Size: SH
  7. Remove the bleed pipe bolts (1).
  8. Remove the bleed pipe hose clamp (2).
  9. Reposition the bleed pipe.
  10. Remove the brake booster vacuum hose from the intake manifold.

    11. Object Number: 1829153 Size: SH
  11. Remove the engine harness retaining clips.

    12. Object Number: 1829177 Size: SH
  12. Remove the upper intake retaining bolts.
  13. Remove the upper intake manifold and gasket. Discard gasket.
  14. If replacing the upper intake manifold complete the following steps:
    15. 14.1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    14.2. Remove the throttle body. Refer to Throttle Body Assembly Replacement .

Installation Procedure

    Object Number: 1829177 Size: SH
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the upper intake manifold.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Apply threadlock to the bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  4. Install the upper intake manifold bolts and tighten to 25 N·m (18 lb ft) .
  5. If the upper manifold was replaced, complete the following steps:
    6. 5.1. Install the throttle body. Refer to Throttle Body Assembly Replacement .
    5.2. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .

    Object Number: 1829153 Size: SH
  6. Install the engine harness retaining clips.
  7. Install the brake booster vacuum hose to the intake manifold.
  8. Install the brake booster vacuum hose to the intake manifold.

    9. Object Number: 1829016 Size: SH
  9. Position the bleed pipe.
  10. Install the bleed pipe hose clamp (2).
  11. Install the bleed pipe bolts (1) and tighten to 10 N·m (89 lb in) .
  12. Connect the coolant hose bleed pipe.

    13. Object Number: 1828971 Size: SH
  13. Connect the EVAP canister purge line.

    14. Object Number: 1828339 Size: SH
  14. Connect the PCV line to the top of the intake manifold .

    15. Object Number: 1828897 Size: SH
  15. Connect the ETC electrical connector.
  16. Install the air cleaner outlet duct.

    17. Object Number: 1828852 Size: SH
  17. Install the fresh air PCV line to the air cleaner inlet duct.
  18. Install the engine cover. Refer to Fuel Injector Sight Shield Replacement .