Exhaust Manifold Removal and Installation: Removal

WARNING: Touching a hot exhaust system component will cause a burn. Do not perform any service work on the exhaust system until the exhaust system is cool.

CAUTION: Applying a shock to the exhaust manifold may cause damage to the three-way catalytic converter inside the exhaust manifold. Handle the exhaust manifold carefully. Be careful not to drop it or hit it against something.

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.