Exhaust Manifold Removal & Installation: Installation

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install new gasket (1) to cylinder head.

Fig 1: Installing New Exhaust Manifold Gasket To Cylinder Head
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust manifold (1). Tighten manifold bolts and nuts to specified torque.

Fig 2: Installing Exhaust Manifold
Courtesy of SUZUKI OF AMERICA CORP.
Install seal ring and install exhaust No.1 pipe (1) to exhaust manifold.
Before installing seal ring, check it for deterioration or damage, and replace as necessary. Use new lock nuts if used.

Tighten pipe fasteners to specified torque.
1. Tightening torque
2. Exhaust No.1 pipe bolt and nut (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fig 3: Tightening Manifold Nuts & Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust manifold stiffener (1), if equipped.
Tighten exhaust manifold stiffener nut and bolt to specified torque.

Fig 4: Installing Exhaust Manifold Stiffener
Courtesy of SUZUKI OF AMERICA CORP.
Install upper cover (2) to exhaust manifold.
Connect heated oxygen sensor-1 coupler (1) and fit coupler to bracket securely.

Fig 5: Installing Upper Cover To Exhaust Manifold & Connecting Heated Oxygen Sensor-1 Coupler
Courtesy of SUZUKI OF AMERICA CORP.
Connect negative cable at battery.
Check exhaust system for exhaust gas leakage.