Exhaust Manifold Removal and Installation: Installation

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

Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe.
Install exhaust manifolds.
- Always install new bolts with pre-coated adhesive to the locations with * mark.
- Tighten manifold nuts to specified torque.
  Tightening torque
  
  Exhaust manifold bolt and nut (a): 30 N.m (3.0 kg-m, 22.0 lb-ft)
Fig 1: Tightening Exhaust Manifold Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Attach exhaust manifold stiffener to transmission.
Install exhaust No.1 pipe (1) and stiffener (3). Tighten exhaust No.1 pipe bolts to specified torque.
Tightening torque

Exhaust No.1 pipe bolt (b): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 2: Tightening Exhaust No.1 Pipe Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Reverse removal procedure to install front propeller shaft, if removed.
When installing propeller shaft, align match mark (1).

Use the following specification to torque universal joint flange.

Tightening torque

Universal joint flange bolt (c): 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 3: Tightening Universal Joint Flange Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Connect EGR pipe to left (No.1) bank exhaust manifold (1).
Install exhaust manifold covers (2).
Install oil level gauge guide (3) using new O-ring.

Fig 4: Installing Exhaust Manifold Covers
Courtesy of SUZUKI OF AMERICA CORP.
Connect oxygen sensor lead wire couplers. Be sure to clamp its lead wires.

Fig 5: Connecting Oxygen Sensor Lead Wire Couplers
Courtesy of SUZUKI OF AMERICA CORP.
Connect negative cable to battery. Upon completion of installation, start engine and check that no exhaust gas leakage exists.