Exhaust Manifold Removal And Installation: Installation

Right side exhaust manifold

Reverse removal procedure for installation noting the following.

• Use new manifold gasket, new EGR pipe gasket and new exhaust No. 1 pipe gaskets.
• Always install new exhaust manifold bolts (1) with pre-coated adhesive.
• Tighten each bolts and nuts to specified torque.

  Tightening torque 

  Exhaust manifold stiffener bolt a: 30 N.m (3.0 kg-m, 21.5 lb-ft) 

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

  Fig 1: Identifying Exhaust Manifold Stiffener Bolt & Exhaust Manifold Bolts

  Courtesy of SUZUKI OF AMERICA CORP.
• Upon completion of installation, start engine and check that no exhaust gas leakage exists.

Left side exhaust manifold

Reverse removal procedure for installation noting the following.

• Use new manifold gasket and new exhaust No. 1 pipe gaskets.
• Always install new exhaust manifold bolts (1) with pre-coated adhesive.
• Tighten each bolts and nuts to specified torque.

  Tightening torque 

  Exhaust manifold stiffener bolt a: 30 N.m (3.0 kg-m, 21.5 lb-ft) 

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

  HO2S-2: 45 N.m (4.5 kg-m, 32.5 lb-ft) 

  Fig 2: Identifying Exhaust Manifold Bolts & Exhaust Manifold Stiffener Bolt

  Courtesy of SUZUKI OF AMERICA CORP.
• Install oil filter referring to ENGINE OIL AND FILTER CHANGE .
• Connect suction hose and discharge hose to A/C compressor, referring to COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION .
• Install steering lower shaft assembly referring to STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
• Upon completion of installation, turn ignition switch to ON position and check that no fuel leakage.
• Start engine and check that no exhaust gas leakage.