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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1191 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the fuel rail cover.
  2. Remove the generator. Refer to GENERATOR in Engine Electrical.
  3. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
    Fig 1: Fuel Rail Cover
    G01971176Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust manifold nuts.
    Fig 2: Exhaust Manifold Nuts
    G01971177Courtesy of GENERAL MOTORS CORP.
  5. Remove the connector position assurance (CPA) lock.
  6. Disconnect the oxygen sensor electrical connector.
  7. Remove the oxygen sensor connector clip at the body.
    NOTE: Refer to OXYGEN SENSOR NOTICE in Cautions and Notices.
  8. Remove the oxygen sensor.
  9. Lower the vehicle.
    Fig 3: Removing Oxygen Sensor Connector Clip At Body
    G01971178Courtesy of GENERAL MOTORS CORP.
  10. Remove the hose clamp at the secondary air injection (AIR) pipe.
  11. Remove the AIR hose from the AIR pipe.
    Fig 4: Removing Hose Clamp At Secondary Air Injection (AIR) Pipe
    G01971179Courtesy of GENERAL MOTORS CORP.
  12. Remove the hose clamps at the right and left check valves.
  13. Remove the AIR injection pipe hose (1) from the right check valve.
  14. Remove the AIR injection pipe hose (3) from the left check valve.
  15. Remove the AIR pipe (2).
    Fig 5: Removing Air Injection Pipe Hose From Right & Left Check Valve
    G01971180Courtesy of GENERAL MOTORS CORP.

    Important:  Do not remove the check valve from the AIR pipe unless valve service is required.

  16. Remove the AIR pipe bolts.
  17. Remove the AIR pipe and gasket. Discard the old gasket
    Fig 6: AIR Pipe Bolts
    G01971181Courtesy of GENERAL MOTORS CORP.
  18. Remove the brake booster vacuum hose from the brake booster.
    Fig 7: Removing Brake Booster Vacuum Hose From Brake Booster
    G01971182Courtesy of GENERAL MOTORS CORP.
  19. Remove the ignition coil bracket studs.
  20. Remove the ignition coil bracket.
  21. Remove the spark plugs. Refer to SPARK PLUGS in Engine Controls - 5.7 L.
    Fig 8: Ignition Coil Bracket Studs
    G01971183Courtesy of GENERAL MOTORS CORP.
  22. Remove the exhaust manifold bolts.
  23. Remove the exhaust manifold, and old gasket. Discard the gasket.
  24. If necessary, remove the exhaust manifold heat shield bolts and shield.
    Fig 9: Exhaust Manifold Bolts
    G01971184Courtesy of GENERAL MOTORS CORP.
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