Exhaust Manifold Removal And Installation: Installation

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

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.