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Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Right Exhaust Crossover Heat Shield
    GM910984Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26) or Fuel Injector Sight Shield Replacement (L32) in Engine Mechanical - 3.8L.
  2. Remove the exhaust crossover heat shield nuts (1).
  3. Remove the exhaust crossover heat shield (2).
    4. Fig 2: Right Exhaust Crossover Pipe Studs
    GM911162Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust crossover pipe studs (3) from the right exhaust manifold.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    6. Fig 3: Right Exhaust Manifold & Catalytic Converter Pipe
    GM911163Courtesy of GENERAL MOTORS CORP.
  6. Remove the exhaust manifold pipe stud nuts (2) and the catalytic converter pipe (3) from the right exhaust manifold.
  7. Lower the vehicle.
  8. Rotate the engine to access the right side of the engine. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.8L.
    9. Fig 4: HO2S Electrical Connector
    GM911055Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
  10. Remove the HO2S electrical connector (1) from the engine sight shield bracket.
  11. Remove the HO2S (2) from the right exhaust manifold. Refer to Heated Oxygen Sensor Replacement - Position 1
  12. Remove the right side spark plugs from cylinders 2, 4 and 6. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
    13. Fig 5: Fuel Injector Sight Shield Bracket
    GM911011Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel injector sight shield bracket nuts (2).
  14. Remove the fuel injector sight shield bracket (1).
    15. Fig 6: Right Engine Lift Bracket
    GM910986Courtesy of GENERAL MOTORS CORP.
  15. Remove the right engine lift bracket bolt (2) and the nut (3).
  16. Remove the right engine lift bracket (1).
    17. Fig 7: Right Exhaust Manifold Heat Shield
    GM911016Courtesy of GENERAL MOTORS CORP.
  17. Remove the right exhaust manifold heat shield bolts (2).
  18. Remove the right exhaust manifold heat shield (1).
  19. Raise the vehicle.
    20. Fig 8: EGR Valve Inlet Adapter Pipe Bolt
    GM911025Courtesy of GENERAL MOTORS CORP.
  20. Remove the exhaust gas recirculation (EGR) valve inlet adapter pipe bolt (1) from the right exhaust manifold.
  21. Lower the vehicle.
    22. Fig 9: Right Exhaust Manifold Gasket
    GM910980Courtesy of GENERAL MOTORS CORP.
  22. Remove the right exhaust manifold studs (4) and the nuts (3).
  23. Remove the right exhaust manifold (2).
  24. Remove the right exhaust manifold gasket (1).
    25. Fig 10: Right Exhaust Manifold Studs
    GM305693Courtesy of GENERAL MOTORS CORP.
  25. Remove the exhaust manifold studs if damaged.
  26. Clean and Inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 3.8L.
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