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Exhaust Manifold Removal and Installation: Removal

  1. Disconnect the negative battery cable.
  2. Disconnect the Heated Oxygen (HO2) sensor connector, if equipped.
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
    Fig 1: Removing/Installing Exhaust Manifold Heat Shield & Bolts
    G04716747Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
    Fig 2: Removing/Installing Exhaust Flex Pipe Retaining Nuts From Exhaust Manifold Studs
    G04716464Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove the exhaust manifold retaining nuts in the sequence shown.
  7. Remove the exhaust manifold.
  8. Remove the exhaust manifold gasket.
  9. Clean the sealing surfaces of the exhaust manifold and the cylinder head.
    Fig 3: Installation Sequence Of Exhaust Manifold Retaining Nuts
    G04716495Courtesy of SUZUKI OF AMERICA CORP.