Exhaust Manifold Removal and Installation: Removal

WARNING: To avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.

CAUTION: Exhaust manifold has three-way catalytic converter which reduce harmful exhaust emissions.
Be careful not to drop exhaust manifold. If it is dropped, inside catalytic converter may be damaged on impact.

1. Disconnect negative (-) cable at battery.
2. Remove right and left side engine under covers.
3. Remove air cleaner assembly. See AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION .
4. Remove condenser cooling fan.
   • Manual A/C model: See CONDENSER COOLING FAN REMOVAL AND INSTALLATION .
   • Auto A/C model: See CONDENSER COOLING FAN REMOVAL AND INSTALLATION .
5. Disconnect ground wire (1) and remove exhaust manifold cover (2).
   Fig 1: Identifying Ground Wire And Manifold Cover

   Courtesy of SUZUKI OF AMERICA CORP.
6. Remove exhaust No. 1 pipe. See EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION .
7. Disconnect A/F sensor connector (1).
8. Loosen exhaust manifold bolts and nuts in numerical order ("1" through "6") as shown in figure, and remove them.
9. Remove exhaust manifold (2), engine hook (3) and gasket from cylinder head.

Fig 2: Identifying Exhaust Manifold Engine Hook And Gasket

Courtesy of SUZUKI OF AMERICA CORP.