Exhaust Manifold Removal & Installation: Removal

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect negative (-) cable at battery.
Remove air cleaner upper case and intake air hose (for right side exhaust manifold removal).
Remove HO2S connectors from bracket, then disconnect them.

Fig 1: Disconnecting HO2S
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect EGR pipe from right (No. 2) bank exhaust manifold (for right side exhaust manifold removal).
Remove oil level gauge guide (3) (for left side exhaust manifold removal).
Detach P/S pump assembly (4) (for left side exhaust manifold removal) referring to P/S PUMP REMOVAL & INSTALLATION .
Remove exhaust manifold covers (2) from exhaust manifolds (1).

Fig 2: Removing Exhaust Manifold Covers From Exhaust Manifolds
Courtesy of SUZUKI OF AMERICA CORP.
Hoist vehicle.
For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facilitate their installation as shown in the figure.

Fig 3: Marking On Joint Flange & Propeller Shaft
Courtesy of SUZUKI OF AMERICA CORP.
For 4WD vehicle, disconnect propeller shaft from front differential.
Remove exhaust No. 1 pipe (1).

Fig 4: Removing Exhaust No. 1 Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Remove exhaust manifold stiffeners (1) from transmission case (3).

Fig 5: Removing Exhaust Manifold Stiffeners From Transmission Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove stabilizer bar mounting bolt and pull down stabilizer bar (for right side exhaust manifold removal) referring to STABILIZER BAR .
Remove exhaust manifolds and their gaskets from cylinder heads.