Inspection Procedure

Fig 1: Identifying Right Exhaust Manifold Components

Courtesy of SUZUKI OF AMERICA CORP.

1. Inspect the right exhaust manifold for the following:
   • Damage or excessive corrosion to the exhaust manifold exterior (1)
   • Damage to the exhaust manifold mounting holes (2)
   • Damage to the threaded holes (3) for the heat shield
   • Damage to the exhaust manifold flange bolt holes (4)
   • Damage to the heated oxygen sensor (HO2S) hole threads (5)
     Fig 2: Identifying Right Exhaust Manifold Mounting Holes & Threaded Holes

     Courtesy of SUZUKI OF AMERICA CORP.
2. Inspect the right exhaust manifold for the following:
   • Damage to the gasket sealing surfaces (1)
   • Damage or restrictions within the exhaust passages (2)
3. Repair or replace the right exhaust manifold and/or components as necessary.
   Fig 3: Measuring Alignment/Surface Flatness Of Exhaust Manifold Flanges Using Straight Edge & Feeler Gauge

   Courtesy of SUZUKI OF AMERICA CORP.
4. Measure the alignment or surface flatness of the exhaust manifold flanges, using a straight edge and a feeler gauge.

   Exhaust manifold surface flatness must not exceed 0.254 mm (0.010 in).

5. If the surface flatness is not within specifications, the exhaust manifold is warped and must be replaced.

Reference: EXHAUST MANIFOLD INSTALLATION - RIGHT SIDE