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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1028 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
    Fig 1: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  4. Raise the transmission off of the transmission support.
    5. Fig 2: Transmission Support Crossmember (6.0L, 6.6L, and 8.1L Engines)
    GM788013Courtesy of GENERAL MOTORS CORP.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. Refer to Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)  or Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) .
  8. If equipped with a 6.0L or 8.1L engine, perform the following:
    1. Remove the clip around the engine harness and the oxygen sensor pigtail.
    2. Disconnect the connector position assurance (CPA) retainer.
    3. Disconnect the oxygen sensor electrical connector.
    4. Remove the oxygen sensor.
    Fig 3: View Of O2 Sensor, Connector, Harness And Retainers
    GM664781Courtesy of GENERAL MOTORS CORP.
    9. Fig 4: Exhaust Manifold Pipe Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM858574Courtesy of GENERAL MOTORS CORP.
  9. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe nuts.
  10. Using the transmission jack, lower the transmission slightly.
    11. Fig 5: Exhaust Muffler Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM694338Courtesy of GENERAL MOTORS CORP.
  11. If equipped with the 6.6L engine, remove the exhaust muffler nuts.
    12. Fig 6: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  12. If equipped with a 6.6L engine, loosen the exhaust pipe clamp.
  13. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
    14. Fig 7: Exhaust Manifold Pipe (6.0L, 6.6L, and 8.1L Engines)
    GM858576Courtesy of GENERAL MOTORS CORP.
  14. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe.
  15. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  16. Discard the exhaust manifold pipe seal.
    17. Fig 8: Exhaust Manifold Pipe (6.0L, With RPO Y91)
    GM858590Courtesy of GENERAL MOTORS CORP.
  17. If equipped with a 6.0L engine, with RPO Y91, remove the exhaust manifold pipe.
  18. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  19. Discard the exhaust manifold pipe seal.
    20. Fig 9: Exhaust Manifold Pipe Hanger And Insulator (6.0L, 6.6L, and 8.1L Engines)
    GM694896Courtesy of GENERAL MOTORS CORP.
  20. If equipped with a 6.6L engine, remove the exhaust manifold pipe.
  21. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
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