Exhaust Manifold Removal and Installation: Installation

Install new manifold gaskets to cylinder heads and No. 1 pipe gasket to exhaust No. 1 pipe.
Install exhaust manifolds.
- Always install new bolts with pre-coated adhesive to the locations with * mark.
- Tighten both manifold nuts and bolts to specified torque.
  Tightening torque
  
  Exhaust manifold bolt and nut (a): 30 N.m (3.0 kg-m, 21.5 lb-ft)
  
  Fig 1: Tightening Manifold Nuts & Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
Install stabilizer bar if it was removed. Refer to STABILIZER BAR .
Install exhaust manifold stiffener(s).
Install exhaust No. 1 pipe (1).
Tighten exhaust No. 1 pipe bolts and nuts to specified torque.

Tightening torque

Exhaust No. 1 pipe bolt and nut (b): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 2: Tightening Exhaust No. 1 Pipe Bolts & Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Reverse removal procedure to install front propeller shaft if removed.
When installing propeller shaft, align match mark (1).

Use the following specification to torque universal joint flange.

Tightening torque

Front propeller shaft flange nuts (c): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 3: Installing Propeller Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Connect EGR pipe to left (No. 1) bank exhaust manifold (1).
Install exhaust manifold covers (2).
Install oil level gauge guide (3) using new O-ring.
Install P/S pump assembly (4) if it was removed. Refer to P/S PUMP REMOVAL AND INSTALLATION .

Fig 4: Installing P/S Pump Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Adjust P/S pump drive belt tension referring to P/S PUMP DRIVE BELT INSPECTION AND ADJUSTMENT .
Connect oxygen sensor lead wire couplers. Be sure to clamp its lead wires.

Fig 5: Connecting Oxygen Sensor Lead Wire Couplers
Courtesy of SUZUKI OF AMERICA CORP.
Connect negative (-) cable to battery.
Upon completion of installation, start engine and check that no exhaust gas leakage exists.