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Exhaust Manifold Removal and Installation: Installation

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe.
  2. 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: Identifying Left & Right Exhaust Manifold, Bolts And Nuts
      G04721674Courtesy of SUZUKI OF AMERICA CORP.
  3. Install stabilizer bar if it was removed. Refer to STABILIZER BAR / BUSHINGS REMOVAL AND INSTALLATION.
  4. Install exhaust manifold stiffener(s).
  5. Install exhaust No.1 pipe (1).

    Tighten exhaust No.1 pipe bolts and nuts to specified torque.

    Tightening torque 

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

    Fig 2: Identifying Exhaust No. 1 Pipe, Exhaust No. 2 Pipe & Exhaust Manifold
    G04721675Courtesy of SUZUKI OF AMERICA CORP.
  6. 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 nut c: 50 N.m (5.0 kg-m, 36.5 lb-ft)

    Fig 3: Identifying Match Mark & Front Propeller Shaft Flange Nut
    G04721676Courtesy of SUZUKI OF AMERICA CORP.
  7. Connect EGR pipe to left (No.1) bank exhaust manifold (1), if it was removed.
  8. Install exhaust manifold covers (2).
  9. Install oil level gauge guide (3) using new O-ring, if it was removed.
  10. Install P/S pump assembly (4) if it was removed. Refer to P/S PUMP REMOVAL AND INSTALLATION.
    Fig 4: Identifying Left Bank Exhaust Manifold, Exhaust Manifold Covers, Oil Level Gauge Guide & P/S Pump Assembly
    G04721677Courtesy of SUZUKI OF AMERICA CORP.
  11. Adjust P/S pump drive belt tension, if it was removed. Refer to P/S PUMP DRIVE BELT INSPECTION AND ADJUSTMENT.
  12. Connect HO2S connectors and attach them to bracket. Be sure to clamp its lead wires.
    Fig 5: Identifying HO2S-1 & HO2S-2
    G04721678Courtesy of SUZUKI OF AMERICA CORP.
  13. Connect negative (-) cable to battery.

    Upon completion of installation, start engine and check that no exhaust gas leakage exists.

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