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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Specifications |
1837490

Fastener Tightening Specifications

Specification
Application Metric English
Catalytic Converter to Exhaust Flexible Pipe Nut 22 N·m 16 lb ft
Catalytic Converter to Exhaust Manifold Nut 50 N·m 37 lb ft
Catalytic Converter Nut 50 N·m 37 lb ft
Dash Panel Heat Shield 10 N·m 89 lb in
Exhaust Manifold Bolt 25 N·m 18 lb ft
Exhaust Manifold Heat Shield Bolt 10 N·m 89 lb in
Exhaust Muffler Clamp 5 N·m 44 lb in
Fuel Tank Strap Bolt 25 N·m 18 lb ft
Rear Exhaust Manifold Heat Shield Bolt 50 N·m 37 lb ft

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 1837170 Page 1 of 3

2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837170

Exhaust Manifold Replacement - Left Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement - Left Side .
2. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Replacement .
3. Remove the catalytic converter to exhaust manifold nuts (1).

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4. Remove the exhaust manifold bolts (1).

Important: Do not reuse the gasket.

5. Remove the exhaust manifold and gasket. Discard the gasket.

Installation Procedure

1. Install one exhaust manifold bolt to the exhaust manifold.

2. Install the NEW exhaust manifold gasket onto the cylinder head and bolt.
3. Install the exhaust manifold (with gasket) to the catalytic converter and the cylinder head.

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Notice: Refer to Fastener Notice in the Preface section.

4. Install the remaining exhaust manifold bolts (1).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

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5. Install the catalytic converter to exhaust manifold nuts (1).

Tighten
Tighten the nuts to 50 N·m (37 lb ft).

6. Install the oil level indicator. Refer to Oil Level Indicator and Tube Replacement .
7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement -
Left Side .

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 1837171 Page 1 of 3

2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837171

Exhaust Manifold Replacement - Right Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement - Right Side .
2. Remove the catalytic converter to exhaust manifold nuts (1).
3. Remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side .

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4. Remove the exhaust manifold bolts (1).

Important: Do not reuse the gasket.

5. Remove the exhaust manifold and gasket out from vehicle. Discard the gasket.

Installation Procedure

1. Install one exhaust manifold bolt (1) to the exhaust manifold.

2. Install the NEW exhaust manifold gasket onto the cylinder head and bolt.
3. Install the exhaust manifold (with gasket) to the catalytic converter and the cylinder head.

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Notice: Refer to Fastener Notice in the Preface section.

4. Install the exhaust manifold bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

5. Install the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side .

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6. Install the catalytic converter nuts (1).

Tighten
Tighten the nuts to 50 N·m (37 lb ft).

7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement -
Right Side .

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837172

Catalytic Converter Replacement - Left Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement - Left Side.
2. Remove the catalytic converter to exhaust manifold nuts (1).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

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4. Disconnect the heated oxygen sensor (HO2S) electrical connector (2) from the engine wiring
harness electrical connector.

5. Remove the left catalytic converter to exhaust flexible pipe bolts.

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6. Remove the catalytic converter from the vehicle.
7. Remove and discard the catalytic converter to exhaust manifold gasket (2).
8. Remove and discard the catalytic converter to exhaust flexible pipe gasket (1).

Installation Procedure

1. Install a NEW catalytic converter to exhaust manifold gasket (2) onto the catalytic converter.
2. Install the catalytic converter to the vehicle.
3. Install a NEW catalytic converter to exhaust flexible pipe gasket (1) between the converter
and the flexible pipe.

Notice: Refer to Fastener Notice in the Preface section.

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4. Install the left catalytic converter to exhaust flexible pipe bolts.

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

5. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector.
6. Lower the vehicle.

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7. Install the catalytic converter to exhaust manifold nuts (1).

Tighten
Tighten the nuts to 50 N·m (37 lb ft).

8. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement -
Left Side.

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837174

Catalytic Converter Replacement - Right Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement - Right Side .
2. Remove the catalytic converter to exhaust manifold nuts (1).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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4. Disconnect heated oxygen sensor (HO2S) electrical connector (2) from the engine wiring
harness electrical connector.

5. Remove the right catalytic converter to exhaust flexible pipe nuts.

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6. Remove the catalytic converter from the vehicle.
7. Remove and discard the catalytic converter to exhaust manifold gasket (1).
8. Remove and discard the catalytic converter to exhaust flexible pipe gasket (2).

Installation Procedure

1. Install a NEW catalytic converter to exhaust manifold gasket (1) onto the catalytic converter.
2. Install the catalytic converter to the vehicle.
3. Install a NEW catalytic converter to exhaust flexible pipe gasket (2) between the converter
and the flexible pipe.

Notice: Refer to Fastener Notice in the Preface section.

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4. Install the right catalytic converter to exhaust flexible pipe nuts.

Tighten
Tighten the nuts to 22 N·m (16 lb ft).

5. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector.
6. Lower the vehicle.

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7. Install the catalytic converter to exhaust manifold nuts (1).

Tighten
Tighten the nuts to 50 N·m (37 lb ft).

8. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement -
Right Side .

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 1837265 Page 1 of 3

2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837265

Exhaust Muffler Replacement

Removal Procedure

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1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Loosen the exhaust muffler clamps.

3. With the aid of an assistant, separate the rubber insulators from the exhaust pipe hangers.
4. With the aid of an assistant, remove the muffler assembly from exhaust flexible pipe and the
vehicle.

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Installation Procedure

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1. With the aid of an assistant, install the muffler assembly to the vehicle and the exhaust
flexible pipe.
2. With the aid of an assistant, install the exhaust pipe hangers to the rubber insulators.

Notice: Refer to Fastener Notice in the Preface section.

3. Tighten the exhaust muffler clamps.

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Tighten
Tighten the clamps to 5 N·m (44 lb in).

4. Lower the vehicle.

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837249

Exhaust Flexible Pipe Replacement

Removal Procedure

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1. Remove the right and left catalytic converter to exhaust flexible pipe bolts and nuts.
2. Remove the flexible pipe insulator from the pipe hanger.

3. Loosen the exhaust muffler clamps.

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4. Separate the exhaust flexible pipe from the catalytic converters.
5. Remove the exhaust flexible pipe from the muffler.
6. Remove and discard the catalytic converter to flexible pipe gaskets.

Installation Procedure

1. Install the exhaust flexible pipe to the muffler.

2. Insert NEW catalytic converter to flexible pipe gaskets between the catalytic converters and
the exhaust flexible pipe.
3. Install the exhaust flexible pipe to the catalytic converters.

Notice: Refer to Fastener Notice in the Preface section.

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4. Tighten the exhaust muffler clamps.

Tighten
Tighten the clamps to 5 N·m (44 lb in).

5. Install the flexible pipe insulator to the pipe hanger.

6. Install the right and left catalytic converter to exhaust flexible pipe bolts.

Tighten
Tighten the bolts to 22 N·m (16 lb ft).

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837393

Catalytic Converter Heat Shield Replacement

Removal Procedure
1. Remove the muffler assembly. Refer to Muffler Replacement .

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Important: Support the fuel tank prior to removing the fuel tank strap bolt.

2. Remove the right fuel tank strap bolt, which also secures the rear of the catalytic converter
heat shield to the underbody.

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Important: The heat shields at the dash panel and the catalytic converter overlap and
utilizing common rivet attachment points.

3. Drill out the rivets.

4. Remove the catalytic converter heat shield.

Installation Procedure

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1. Position the catalytic converter heat shield, and insert the catalytic converter heat shield
between the underbody and the dash panel heat shield.
2. Install the NEW rivets.

Notice: Refer to Fastener Notice in the Preface section.

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3. Install the fuel tank strap bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

4. Install the muffler assembly. Refer to Muffler Replacement .

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837394

Exhaust Heat Shield Replacement - Dash Panel

Removal Procedure

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1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the dash panel heat shield nut.

Important: The heat shields at the dash panel and the catalytic converter overlap and
utilizing common rivet attachment points.

3. Drill out the dash panel heat shield rivets.

4. Remove the dash panel heat shield.

Installation Procedure

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1. Position the dash panel heat shield to the underbody, installing the shield over the stud.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the dash panel heat shield nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).

3. Install NEW rivets.

4. Lower the vehicle.

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837395

Exhaust Manifold Heat Shield Replacement

Removal Procedure

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1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the rear exhaust manifold heat shield bolts and shield.

Installation Procedure
Notice: Refer to Fastener Notice in the Preface section.

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1. Position the rear exhaust manifold heat shield to the engine and install the bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

2. Lower the vehicle.

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837397

Exhaust Manifold Heat Shield Replacement - Right Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the fuel injector sight shield, if necessary. Refer to Fuel Injector Sight Shield
Replacement .
2. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor
(HO2S) electrical connector (2).
3. Remove the HO2S electrical connector retainer from the camshaft cover.

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4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield, sliding the shield up over the HO2S pigtail.

Installation Procedure

1. Install the exhaust manifold heat shield, sliding the shield down over the HO2S pigtail.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the exhaust manifold heat shield bolts.

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Tighten
Tighten the bolts to 10 N·m (89 lb in).

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3. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector
(2).
4. Install the HO2S electrical connector retainer to the camshaft cover.
5. Install the fuel injector sight shield, if necessary. Refer to Fuel Injector Sight Shield
Replacement .

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2008 Suzuki XL-7 AWD | XL-7 (VIN L) Service Manual | Engine | Engine Exhaust | Repair Instructions |
1837398

Exhaust Manifold Heat Shield Replacement - Left Side

Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

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1. Remove the fuel injector sight shield, if necessary. Refer to Fuel Injector Sight Shield
Replacement .
2. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor
(HO2S) electrical connector (4).
3. Remove the HO2S electrical connector retainer (5) from the retainer clip.

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4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield, sliding the shield up over the HO2S pigtail.

Installation Procedure

1. Install the exhaust manifold heat shield, sliding the shield down over the HO2S pigtail.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the exhaust manifold heat shield bolts.

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Tighten
Tighten the bolts to 10 N·m (89 lb in).

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3. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector
(4).
4. Install the HO2S electrical connector retainer (5) to the retainer clip.
5. Install the fuel injector sight shield, if necessary. Refer to Fuel Injector Sight Shield
Replacement .

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