LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 561 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Right (3.8L) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Buick Regal and 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable.
  2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)
  3. Remove the exhaust crossover pipe from the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement (3.1L)  or Exhaust Crossover Pipe Replacement (3.8L) 
  4. Raise and support the vehicle.
  5. Remove the 3-way catalytic converter from the right exhaust manifold. Refer to Catalytic Converter Replacement (3.1 L)  or Catalytic Converter Replacement (3.8L) 
  6. Remove the EGR adapter pipe from the right exhaust manifold.
    7. Fig 1: EGR Adapter Pipe And Bolt
    G01766065Courtesy of GENERAL MOTORS CORP.
  7. Lower the vehicle.
  8. Remove the wiring harness and the heater hose retaining clips from the fuel injector sight shield bracket.
  9. Remove the right spark plug wires.
  10. Remove the engine lift bracket bolt and the nut.
  11. Remove the engine lift bracket.
    Fig 2: Engine Lift Bracket
    G01766066Courtesy of GENERAL MOTORS CORP.
  12. Remove the fuel injector sight shield bracket nuts.
  13. Remove the fuel injector sight shield bracket.
    Fig 3: Fuel Injector Sight Shield Bracket And Nuts
    G01766067Courtesy of GENERAL MOTORS CORP.
  14. Remove the exhaust manifold bolts and the nuts, except for the bolt behind the heated oxygen sensor.
  15. Rotate the engine forward for access. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS
  16. Disconnect the heated oxygen sensor electrical connector.
  17. Remove the remaining bolt and the exhaust manifold.
  18. Remove the exhaust manifold gasket.
    Fig 4: Exhaust Manifold And Gasket
    G01766068Courtesy of GENERAL MOTORS CORP.
  19. Remove the upper exhaust manifold heat shield.
    Fig 5: Upper Exhaust Manifold Heat Shield
    G01766069Courtesy of GENERAL MOTORS CORP.
  20. Remove the lower exhaust manifold heat shield.
    21. Fig 6: Lower Exhaust Manifold Heat Shield
    G01766070Courtesy of GENERAL MOTORS CORP.
  21. Remove the heated oxygen sensor from the exhaust manifold. Refer to HEATED OXYGEN SENSOR
  22. Remove the exhaust manifold studs if damaged.
  23. Clean and inspect the exhaust manifold. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
    Fig 7: Exhaust Manifold Studs
    G01766071Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals