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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 800 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
  2. Disconnect the engine coolant temperature (ECT) sensor.
    Fig 1: Disconnecting Engine Coolant Temperature (ECT) Sensor
    G01644680Courtesy of GENERAL MOTORS CORP.
  3. Raise the vehicle. Refer to JACKING AND LIFTING - 2WD in General Information.
  4. Remove the left front tire. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  5. Remove the left fender wheelhouse extension.
    Fig 2: Removing Left Fender Wheelhouse Extension
    G01644681Courtesy of GENERAL MOTORS CORP.
  6. Remove the catalytic converter assembly. Refer to CATALYTIC CONVERTER REPLACEMENT (RWD)  or CATALYTIC CONVERTER REPLACEMENT (A4WD)  .
  7. Remove the spark plug wires from the spark plugs. Refer to SPARK PLUG WIRE in Removal and Installation in Engine Performance.
  8. Remove the spark plug wire support bolts.
  9. Remove the spark plug wire support with the spark plug wires.
    Fig 3: Removing Spark Plug Wire Support
    G01644682Courtesy of GENERAL MOTORS CORP.
  10. Remove the front 4 exhaust manifold bolts through the wheelhouse.
  11. Remove the 2 rear exhaust manifold bolts through the engine cover opening.
  12. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle.
    Fig 4: Removing Exhaust Manifold, Gaskets And Spark Plug Wire Shields
    G01644683Courtesy of GENERAL MOTORS CORP.
  13. Clean all gasket surfaces.
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