Suzuki Vitara, Grand Vitara, XL7 2000-06

Exhaust Manifold

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Removal & Installation



1.6L, 2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar, if equipped
     
    Air intake assembly and bracket
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Exhaust front pipe
     
    Exhaust manifold heat shield
     
    Exhaust manifold bracket, if equipped
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Tighten the fasteners to 13-20 ft. lbs. (18-28 Nm).
     
    Exhaust manifold bracket, if equipped. Tighten the bolts to 36-43 ft. lbs. (50-60 Nm).
     
    Exhaust manifold heat shield
     
    Exhaust front pipe. Tighten the fasteners to 29-43 ft. lbs. (40-60 Nm).
     
    HO 2 S sensor connector
     
    Air intake assembly and bracket
     
    Strut tower bar, if equipped. Tighten the fasteners to 66 ft. lbs. (90 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar
     
    Air intake assembly
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Oil dipstick tube
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Exhaust manifold heat shields
     
    Evaporative Emissions (EVAP) canister
     
    Front driveshaft, if equipped
     
    Exhaust front pipe
     
    Exhaust manifold brace
     
    Exhaust manifolds
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds with new gaskets. Tighten the nuts to 21 ft. lbs. (30 Nm).
     
    Exhaust manifold brace
     
    Exhaust front pipe. Tighten the fasteners to 37 ft. lbs. (50 Nm).
     
    Front driveshaft, if equipped
     
    EVAP canister
     
    Exhaust manifold heat shields
     
    EGR pipe
     
    Oil dipstick tube
     
    HO 2 S sensor connectors
     
    Air intake assembly
     
    Strut tower bar
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Strut tower bar
     
    Air intake assembly
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Oil dipstick tube
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Exhaust manifold heat shields
     
    Evaporative Emissions (EVAP) canister
     
    Front driveshaft, if equipped
     
    Exhaust front pipe
     
    Exhaust manifold brace
     
    Exhaust manifolds
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds with new gaskets. Tighten the nuts to 21 ft. lbs. (30 Nm).
     
    Exhaust manifold brace
     
    Exhaust front pipe. Tighten the fasteners to 37 ft. lbs. (50 Nm).
     
    Front driveshaft, if equipped
     
    EVAP canister
     
    Exhaust manifold heat shields
     
    EGR pipe
     
    Oil dipstick tube
     
    HO 2 S sensor connectors
     
    Air intake assembly
     
    Strut tower bar
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove air cleaner upper case and intake air hose (for right side exhaust manifold removal).
  4.  
  5. Remove HO2S connectors from bracket, then disconnect them.
  6.  
  7. Disconnect EGR pipe from right (No.2) bank exhaust manifold (for right side exhaust manifold removal).
  8.  
  9. Remove oil level gauge guide (for left side exhaust manifold removal).
  10.  
  11. Detach P/S pump assembly (for left side exhaust manifold removal).
  12.  
  13. Remove exhaust manifold covers from exhaust manifolds.
  14.  
  15. Hoist vehicle.
  16.  
  17. For 4WD vehicle, before disconnecting front propeller shaft, put match mark on joint flange and propeller shaft to facilitate their installation.
  18.  
  19. For 4WD vehicle, disconnect propeller shaft from front differential.
  20.  
  21. Remove exhaust No.1 pipe.
  22.  
  23. Remove exhaust manifold stiffeners from transmission case.
  24.  
  25. Remove stabilizer bar mounting bolt and pull down stabilizer bar (for right side exhaust manifold removal)
  26.  
  27. Remove exhaust manifolds and their gaskets from cylinder heads.
  28.  

To install:

  1. Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe.
  2.  
  3. Install exhaust manifolds.
  4.  
  5. Always install new bolts with pre-coated adhesive.
  6.  
  7. Tighten both manifold nuts and bolts to 21.5 ft. lbs. (30 Nm).
  8.  
  9. Install stabilizer bar if it was removed.
  10.  
  11. Install exhaust manifold stiffener.
  12.  
  13. Install exhaust No.1 pipe.
  14.  
  15. Tighten exhaust No.1 pipe bolts and nuts to 36.5 ft. lbs. (50 Nm).
  16.  
  17. Reverse removal procedure to install front propeller shaft if removed.
  18.  
  19. When installing propeller shaft, align match mark.
  20.  
  21. Tighten universal joint flange to 36.5 ft. lbs. (50 Nm).
  22.  
  23. Connect EGR pipe to left (No.1) bank exhaust manifold, if it was removed.
  24.  
  25. Install exhaust manifold covers.
  26.  
  27. Install oil level gauge guide using new O-ring, if it was removed.
  28.  
  29. Install P/S pump assembly if it was removed.
  30.  

Left Manifold
  1. Disconnect the negative battery cable.
  2.  
  3. Release fuel pressure in fuel feed line.
  4.  
  5. Evacuate A/C system.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  6.  
  7. Disconnect fuel feed hose and fuel return hose.
  8.  
  9. Disconnect brake booster hose, vacuum tank hose and EVAP canister purge valve hose from intake manifold and fuel No.2 pipe.
  10.  
  11. Disconnect vacuum hose from IMT valve, and remove vacuum tank assembly.
  12.  
  13. Remove steering lower shaft assembly.
  14.  
  15. Disconnect suction hose and discharge hose from A/C compressor.
  16.  
  17. Remove oil filter.
  18.  
  19. Remove A/F sensor connector and HO2S-2 connector from bracket, then disconnect them.
  20.  
  21. Remove engine hook.
  22.  
  23. Remove oil level gauge and oil level gauge guide.
  24.  
  25. Remove exhaust manifold cover.
  26.  
  27. Remove exhaust No.1 pipe.
  28.  
  29. Remove exhaust manifold stiffener.
  30.  
  31. Remove HO2S from exhaust manifold.
  32.  
  33. Remove exhaust manifold and its gasket from cylinder head.
  34.  

To install:

  1. Reverse removal procedure for installation noting the following.
  2.  
  3. Use new manifold gasket, and new exhaust No.1 pipe gaskets.
  4.  
  5. Always install new exhaust manifold bolts with pre-coated adhesive.
  6.  
  7. Tighten manifold stiffener bolts to 21.5 ft. lbs. (30 Nm).
  8.  
  9. Tighten No.1 pipe bolts and nuts to 36.5 ft. lbs. (50 Nm).
  10.  
  11. Vacuum and recharge A/C system.
  12.  
  13. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Left manifold and bolts a-b shown

  14.  
  15. Upon completion of installation, start engine and check that no exhaust gas leakage exists.
  16.  

Right Manifold
  1. Disconnect the negative battery cable.
  2.  
  3. Remove battery and battery tray.
  4.  
  5. Remove air cleaner assembly and air cleaner outlet hose.
  6.  
  7. Remove A/F sensor connector and HO2S-2 connector from bracket, then disconnect them.
  8.  
  9. Disconnect EGR pipe from exhaust manifold.
  10.  
  11. Remove exhaust manifold cover.
  12.  
  13. Remove exhaust No.1 pipe.
  14.  
  15. Remove exhaust manifold stiffener
  16.  
  17. Remove exhaust manifold and its gasket from cylinder head.
  18.  

To install:

  1. Reverse removal procedure for installation noting the following.
  2.  
  3. Use new manifold gasket, new EGR pipe gasket and new exhaust No.1 pipe gaskets.
  4.  
  5. Always install new exhaust manifold bolts with pre-coated adhesive.
  6.  
  7. Tighten manifold stiffener bolts to 21.5 ft. lbs. (30 Nm).
  8.  
  9. Tighten No.1 pipe bolts and nuts to 36.5 ft. lbs. (50 Nm).
  10.  
  11. Connect the negative battery cable.

    Click image to see an enlarged view

    Fig. Right manifold and bolts a-b shown

  12.  
  13. Upon completion of installation, start engine and check that no exhaust gas leakage exists.
  14.  

 
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