Get Exhaust System Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

EXHAUST SYSTEM 6K-1

SECTION 6K

EXHAUST SYSTEM

CONTENTS

GENERAL DESCRIPTION 6K-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 6K-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6K-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAUTION:

THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY. USE OF

LEADED AND/OR LOW LEAD FUEL CAN RESULT IN DAMAGE AND REDUCE THE EFFECTIVE-

NESS OF THE CATALYTIC CONVERTER.

6K-2 EXHAUST SYSTEM

GENERAL DESCRIPTION

The exhaust system consists of an exhaust manifold, exhaust pipes, a catalyst case a muffler and seal, gaskets

and etc., and catalyst case has the three-way catalytic converter (TWC).

The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels

of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.

: Tightening Torque

: Do not reuse

1. Exhaust manifold cover

2. Exhaust manifold cover bolt

3. Exhaust manifold gasket

4. Exhaust manifold

5. Oxygen sensor

6. Exhaust manifold nut

7. Seal ring

8. Exhaust pipe bolt

9. Exhaust pipe

10. Rubber mounting

11. Mounting bolt

12. Exhaust pipe nut

13. Gasket

14. Muffler

15. Exhaust manifold lower cover

16. Exhaust manifold bolt

17. Catalyst case

MAINTENANCE

WARNING:

To avoid the danger of being burned, do not touch the ex-

haust system when the system is hot. Any service on the

exhaust system should be performed when the system

is cool.

At every interval of periodic maintenance service, and when ve-

hicle is raised for other service, check exhaust system as follows:

D Check rubber mountings for damage, deterioration, and out of

position.

D Check exhaust system for leakage, loose connection, dent and

damage.

If bolts or nuts are loosened, tighten them to specified torque.

Refer to GENERAL DESCRIPTION in this section for torque

data.

D Check nearby body areas for damaged, missing, or misposi-

tioned part, open seam, hole, loose connection or any other de-

fect which could permit exhaust fumes to seep into vehicle.

D Make sure that exhaust system components have enough clear-

ance from underbody to avoid overheating and possible dam-

age to passenger compartment carpet.

D Any defect should be fixed at once.

EXHAUST SYSTEM 6K-3

ON-VEHICLE SERVICE

WARNING:

To avoid the danger of being burned, do not touch the ex-

haust system when the system is hot. Any service on the

exhaust system should be performed when the system

is cool.

EXHAUST MANIFOLD

Refer to Section 6A for removal and installation procedures of ex-

haust manifold.

D Check gasket and seal for deterioration or damage.

Replace them as necessary.

EXHAUST PIPE

For replacement of exhaust pipe, be sure to hoist vehicle and ob-

serve WARNING under “Maintenance” and the following.

CAUTION:

Exhaust pipe have three way catalytic converter in it, it

should not be exposed to any impulse.

Be careful not to drop it or hit it against something.

D Tighten bolts and nuts to specified torque when reassembling.

Refer to GENERAL DESCRIPTION in this section for location of

bolts and nuts.

D After installation, start engine and check each joint of exhaust

system for leakage.

6K-4 EXHAUST SYSTEM

Exhaust System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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