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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 Replacement - Right (8.1L Engine) >> 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. Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  2. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.
    IMPORTANT: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug or the wire could be damaged.
  3. Remove the spark plug wires from the spark plugs and ignition coils.
    Fig 1: View Of Spark Plug Wires (Right)
    GM470704Courtesy of GENERAL MOTORS CORP.
  4. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.
  5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    6. Fig 2: Exhaust Manifold Heat Shield (8.1L Engine)
    GM858564Courtesy of GENERAL MOTORS CORP.
  6. Remove the exhaust manifold heat shield bolts and nuts.
  7. Remove the exhaust manifold heat shield.
  8. Lower the vehicle.
    9. Fig 3: View Of Exhaust Manifold Assembly (8.1L Engine)
    GM470719Courtesy of GENERAL MOTORS CORP.
  9. Remove the exhaust manifold bolt and nuts.
  10. Remove the exhaust manifold.
  11. Remove and discard the exhaust manifold gasket.
  12. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection .
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