Exhaust Manifold Removal and Installation: Installation

Install new gasket (1) to cylinder head.

Fig 1: Installing Gasket To Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust manifold (1).
Tighten manifold bolts and nuts with specified torque and specified tightening order.

Tightening torque

Exhaust manifold bolt and nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Tightening order

A --> B --> C --> D --> E --> F --> G --> H --> I

Fig 2: Installing Exhaust Manifold Bolts And Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Install engine right mounting bracket (1) and new bracket bolts.
Tighten bracket bolts to specified torque.

Tightening torque

Engine right mounting bracket bolt a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

CAUTION: Use new engine right mounting bracket bolt. Reusing bolt may result exhaust leakage.

Fig 3: Installing Engine Right Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Install engine right mounting No.1 bracket (1).
Tighten bolts and nut to specified torque.

Tightening torque

Engine right mounting No.1 bracket bolt and nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Fig 4: Installing Engine Right Mounting No. 1 Bracket
Courtesy of SUZUKI OF AMERICA CORP.
Install air cleaner case assembly and air cleaner outlet hose.
Install new pipe gasket and exhaust No.1 pipe (2).
Tighten exhaust pipe nuts and bolts to specified torque.

Tightening torque

Exhaust manifold to No.1 pipe nut a: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Exhaust No.1 pipe to No.2 pipe bolt b: 43 N.m (4.3 kg-m, 31.5 lb-ft)
Install exhaust pipe No.1 stiffener (3).
Tighten exhaust pipe No.1 stiffener bolts (d) first and next (c) with specified torque.

Tightening torque

Exhaust No.1 pipe stiffener bolt c: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Exhaust No.1 pipe stiffener bolt d: 55 N.m (5.5 kg-m, 40.0 lb-ft)

Fig 5: Installing Exhaust Pipe No. 1 Stiffener
Courtesy of SUZUKI OF AMERICA CORP.
Install engine under cover (Right side).
Install exhaust manifold cover (1).
Connect heated oxygen sensor couplers (2) and A/C magnet clutch coupler (3).

Fig 6: Installing Exhaust Manifold Cover
Courtesy of SUZUKI OF AMERICA CORP.
Connect negative cable at battery.
Check exhaust system for exhaust gas leakage.