Exhaust Manifold Removal and Installation: Removal

Disconnect negative (-) cable at battery.
Remove air cleaner upper case and intake air hose if right side exhaust manifold is removed.
Detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers.

Fig 1: Disconnecting Oxygen Sensor Lead Wires
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect EGR pipe from right (No. 2) bank exhaust manifold if right side exhaust manifold is removed.
Remove oil level gauge guide (3) if left side exhaust manifold is removed.
Detach P/S pump assembly as the following, if left side exhaust manifold is removed.
1. Loosen P/S pump drive belt by loosening tensioner bolt.
2. Remove P/S pump mounting bolts.
3. Detach P/S pump assembly with its hoses from cylinder block.
Remove exhaust manifold covers (2) from exhaust manifolds (1).

Fig 2: Removing Exhaust Manifold Covers
Courtesy of SUZUKI OF AMERICA CORP.
Hoist vehicle.
For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facilitate their installation as shown in the figure.

Fig 3: Marking On Joint Flange And Propeller Shaft
Courtesy of SUZUKI OF AMERICA CORP.
For 4WD vehicle, disconnect propeller shaft from front differential.
Remove exhaust No. 1 pipe (1).

Fig 4: Removing Exhaust No. 1 Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Remove exhaust manifold stiffeners (1) from transmission case (3).

Fig 5: Removing Exhaust Manifold Stiffeners
Courtesy of SUZUKI OF AMERICA CORP.
Remove stabilizer bar mounting bolt and pull down stabilizer bar if right side exhaust manifold is removed.
Remove exhaust manifolds and their gaskets from cylinder heads.