How to Replace the Exhaust Manifold in a Geo Tracker

Chevrolet introduced the Geo Tracker as part of an international line. While it didn't make it into the new millennium name Geo Tracker, it lived on for several years as the Suzuki Vitara, produced from 1989 to 1997 with a 1.6 four-liter engine that offers in fuel economy what it lacked in power. Here are the steps to guide you through replacing the exhaust manifold.

Instructions

Remove the Exhaust Manifold

1

Take the negative battery cable from the terminal. Remove the air cleaner outlet tube and the inlet pipe, then take out the connector to the oxygen sensor wiring harness. Disconnect the air intake case support brace.

2

Separate the exhaust manifold shield from the engine after removing the brace. Take off the mounting nuts on the exhaust pipe and detach the pipe.

3

Loosen the exhaust manifold bolts and nuts and remove them. Take the exhaust manifold from the cylinder head. Pull out the old gasket and discard it.

4

Clean the mating surfaces thoroughly to remove any carbon deposits, debris and old gasket material. Wipe the surfaces with solvent and check for damage.

Install the Exhaust Manifold

5

Position the new exhaust manifold-to-cylinder gasket on the head studs and then align the exhaust manifold on it. Working out from the center, torque the fasteners to 159 to 248 inch pounds in three or four passes.

6

Replace the air intake case support bracket. Torque the bolts to 159 to 248 pounds in three or four passes.

7

Use a new gasket and reattach the exhaust pipe. Torque the nuts to 29 to 43 foot pounds.

8

Put the exhaust manifold brace in place. Torque the brace-to-engine block bolt to 36.5 to 43 ft. lbs. and the brace-to-manifold nut to 29 to 43 ft. lbs.

9

Set the cover on the exhaust manifold. Tighten the bolts.

10

Reattach the oxygen sensor lead wire to the harness. Connect the air cleaner outlet tube and the inlet pipe.

11

Connect the negative battery cable to the terminal. Start the engine. Check for exhaust leaks.