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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1404 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Right (3.1L) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT in Removal & Installation - A/T.
  3. Remove the accelerator and cruise control cables with the bracket from the throttle body.
  4. Rotate the engine for service access. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS in Engine Mechanical - 3.1L.
  5. Remove the manifold absolute pressure (MAP) sensor. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Removal & Installation.
    Fig 1: Removing Manifold Absolute Pressure (MAP) Sensor
    G01969144Courtesy of GENERAL MOTORS CORP.
  6. Remove the ignition control module and the ignition control module bracket. Refer to IGNITION CONTROL MODULE
  7. Disconnect the heated oxygen (HO2S) sensor electrical connector.
  8. Remove the thermostat bypass pipe. Refer to THERMOSTAT BYPASS PIPES REPLACEMENT in Engine Cooling.
  9. Remove the exhaust crossover pipe heat shield bolts.
    Fig 2: Removing Exhaust Crossover Pipe Heat Shield & Bolts
    G01969145Courtesy of GENERAL MOTORS CORP.
  10. Remove the exhaust crossover pipe heat shield.
  11. Remove the exhaust crossover pipe nuts from the right exhaust manifold.
    Fig 3: Removing Exhaust Crossover Pipe & Nuts
    G01969146Courtesy of GENERAL MOTORS CORP.
  12. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  13. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (3.1L)  or CATALYTIC CONVERTER REPLACEMENT (3.8L)  .
  14. Remove the exhaust gas recirculation (EGR) pipe from the right exhaust manifold. Refer to EGR VALVE PIPE
  15. Remove the right exhaust manifold upper heat shield bolts.
    Fig 4: Removing Right Exhaust Manifold Upper Heat Shield & Bolts
    G01969147Courtesy of GENERAL MOTORS CORP.
  16. Remove the right exhaust manifold upper heat shield.
  17. Remove the right exhaust manifold lower heat shield bolts.
    Fig 5: Removing Right Exhaust Manifold Lower Heat Shield & Bolts
    G01969148Courtesy of GENERAL MOTORS CORP.
  18. Remove the right exhaust manifold lower heat shield.
  19. Remove the right exhaust manifold nuts.
    Fig 6: Removing Right Exhaust Manifold, Nuts & Gasket
    G01969149Courtesy of GENERAL MOTORS CORP.
  20. Remove the right exhaust manifold.
  21. Remove the right exhaust manifold gasket.
  22. Clean and inspect the right exhaust manifold. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION in Engine Mechanical - 3.1L.
  23. If replacing the right exhaust manifold remove the heated oxygen (HO2S) sensor. Refer to HEATED OXYGEN SENSOR in Removal & Installation.
    Fig 7: Removing Heated Oxygen Sensor (HO2S)
    G01969150Courtesy of GENERAL MOTORS CORP.
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