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Engine Exhaust System: Removal & Installation Suzuki Equator I

Exhaust 3 illustrations ~488 words

INSTALLATION

installation is in the reverse order of removal.

Scheme 1

Scheme 1: Exhaust Manifold
Scheme 1: Exhaust Manifold
  1. If stud bolts were removed, install them and tighten to the specified torque. Exhaust manifold stud bolt: 14.7 N.m (1.5 kg-m, 11 ft-lb)
  2. Tighten nuts in numerical order as shown.
  3. Tighten nuts in numerical order as shown again.

Removal

WARNINGPerform the work when the exhaust and cooling system have cooled sufficiently.
  1. Remove the front wheel and tire. Refer to «WHEEL AND TIRE ASSEMBLY: ROTATION»(ref-375729-S18715319452010102800000) .
  2. Remove the front fender protector. Refer to «FRONT FENDER PROTECTOR: REMOVAL AND INSTALLATION»(ref-375735-S35289178892010102800000) .
  3. Remove the exhaust manifold cover bolts.
  4. Remove the center exhaust tube, main muffler and front exhaust tube. Refer to «EXHAUST SYSTEM: EXPLODED VIEW»(ref-375741-S34517681292010102800000) .
  5. Disconnect the air fuel ratio sensor 1 harness connector.
  6. Remove the three way catalyst nuts and remove the three way catalyst.
  7. Remove the air fuel ratio sensor 1 using Tool, if necessary. Tool number : KV991J0050 (J-44626) CAUTION: Be careful not to damage air fuel ratio sensor 1. CAUTION: Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.

Installation is in the reverse order of removal.

  1. Tighten air fuel ratio sensor 1 to specification, if removed.

Air fuel ratio sensor : 50.0 N.m (5.1 kg-m, 37 ft-lb)

CAUTIONDo not over tighten air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1, resulting in the "MIL" coming on. Before installing a new air fuel ratio sensor 1, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant. Oxygen sensor thread cleaner: - (J-43897-12) Oxygen sensor thread cleaner: - (J-43897 18)

REMOVAL (LH)

WARNINGPerform the work when the exhaust and cooling system have cooled sufficiently.

Scheme 2

Scheme 2
Scheme 2
  1. Remove engine room cover. Refer to «ENGINE ROOM COVER: REMOVAL AND INSTALLATION»(ref-375721-S37910005862010102800000) .
  2. Remove air cleaner case (upper) and air duct and resonator assembly. Refer to [ «AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION»(ref-375720-S00045471172010102800000) ]
  3. Remove engine under cover. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000) .
  4. Partially drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-375748-S18727906452010102800000) .
  5. Remove three way catalyst (LH). Refer to «Three Way Catalyst: Removal and Installation [VQ40DE]»(ref-375741-S24501766442010111100000) .
  6. Remove exhaust manifold cover (LH).
  7. Remove oil level gauge and oil level gauge guide. Refer to «OIL PAN AND OIL STRAINER: EXPLODED VIEW»(ref-375753-S22556863172010102800000) .
  8. Disconnect water hoses at heater pipe. Refer to «WATER OUTLET AND WATER PIPING: EXPLODED VIEW»(ref-375748-S03009849622010102800000) .
  9. Remove heater pipe from cylinder head (LH). Refer to «WATER OUTLET AND WATER PIPING: EXPLODED VIEW»(ref-375748-S03009849622010102800000) .
  10. Loosen nuts in reverse order as shown. <= : Front NOTE: Disregard the numerical order No. 7 and 8 in removal.
  11. Remove exhaust manifold (LH).
  12. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 3

Scheme 3: Surface Distortion
Scheme 3: Surface Distortion
  1. Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge. Limit: 0.3 mm (0.012 in)
  2. If it exceeds the limit, replace exhaust manifold.

INSTALLATION (LH)

Installation is in the reverse order of removal.

INSTALLATION (RH)

Installation is in the reverse order of removal.

Note. If necessary, a crowfoot may be used to tighten the exhaust manifold nuts.

Exhaust System: Removal and Installation

WARNINGPerform the operation with the exhaust system fully cooled. The system will be hot just after the engine stops. Be careful not to cut your hand on the heat insulator edge.
CAUTIONBe sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape.

Remove exhaust system components using power tool.

  1. Remove heated oxygen sensor using Tool as needed. Tool number: KV10114400 (J-38365)

Installation is in the reverse order of removal.

CAUTIONAlways replace exhaust gaskets with new ones when reassembling. Before installing a new heated oxygen sensor, clean and lube the exhaust tube threads using suitable tool. Oxygen sensor thread cleaner: - (J-43897-18) Oxygen sensor thread cleaner: - (J-43897-12) Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; install a new one. Do not over-tighten the heated oxygen sensor. Doing so may damage the heated oxygen sensor, resulting in the MIL coming on. If any mounting insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the mounting insulators, clean and inspect them. Temporarily tighten the nuts on the exhaust manifold side and the bolts on the vehicle side. Check each part for interference with other components, and then tighten the nuts and bolts to specification.

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