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HOMESERVICE MANUALSGMC1999FORWARD CONTROL 5.7 R, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 802 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L)REMOVAL PROCEDURE
1999 GMC Forward Control 5.7 R, Automatic

Removal Procedure

1999 GMC Forward Control 5.7 R, AutomaticSECTION 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. Remove the cross vehicle brace. Refer to BRACE REPLACEMENT - CROSS VEHICLE in Body Front End.
  2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.8L.
  3. Remove the exhaust crossover heat shield nuts.
    Fig 1: Removing Exhaust Crossover Heat Shield & Nuts
    G01969158Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust crossover heat shield.
  5. Remove the exhaust crossover pipe bolts from the right exhaust manifold.
    Fig 2: Removing Exhaust Crossover Pipe & Bolts
    G01969159Courtesy of GENERAL MOTORS CORP.
  6. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  7. Remove the exhaust manifold pipe stud nuts and the catalytic converter pipe from the right exhaust manifold.
    Fig 3: Removing Exhaust Manifold Pipe Stud Nuts & Catalytic Converter Pipe
    G01969160Courtesy of GENERAL MOTORS CORP.
  8. Remove the exhaust gas recirculation (EGR) valve inlet adapter pipe bolt from the right exhaust manifold.
    9. Fig 4: Removing Exhaust Gas Recirculation (EGR) Valve Inlet Adapter Pipe Bolt
    G01969161Courtesy of GENERAL MOTORS CORP.
  9. Lower the vehicle.
  10. Rotate the engine to access the right side of the engine. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS in Engine Mechanical - 3.8L.
  11. Disconnect the heated oxygen (HO2S) sensor electrical connector (4).
    Fig 5: Disconnecting Heated Oxygen (HO2S) Sensor Electrical Connector
    G01969162Courtesy of GENERAL MOTORS CORP.
  12. Remove the heated oxygen (HO2S) sensor electrical connector (4) from the engine sight shield bracket (1).
  13. Remove the right side spark plugs from cylinders 2, 4 and 6. Refer to SPARK PLUGS in Self-Diagnostics - 3.8L.
  14. Remove the right engine lift bracket bolt and the nut.
    Fig 6: Removing Right Engine Lift Bracket, Bolt & Nut
    G01969163Courtesy of GENERAL MOTORS CORP.
  15. Remove the right engine lift bracket.
  16. Remove the fuel injector sight shield bracket nuts.
    Fig 7: Removing Fuel Injector Sight Shield Bracket & Nuts
    G01969164Courtesy of GENERAL MOTORS CORP.
  17. Remove the fuel injector sight shield bracket.
  18. Remove the right exhaust manifold bolts and the nuts.
    Fig 8: Removing Right Exhaust Manifold, Bolts, Nuts & Gaskets
    G01969165Courtesy of GENERAL MOTORS CORP.
  19. Remove the right exhaust manifold.
  20. Remove the right exhaust manifold gasket.
  21. Remove the upper right exhaust manifold heat shield.
    Fig 9: Removing Upper Right Exhaust Manifold Heat Shield
    G01969166Courtesy of GENERAL MOTORS CORP.
  22. Remove the lower right exhaust manifold heat shield.
    Fig 10: Removing Lower Right Exhaust Manifold Heat Shield
    G01969167Courtesy of GENERAL MOTORS CORP.
  23. If replacing the right exhaust manifold remove the heated oxygen (HO2S) sensor from the right exhaust manifold. Refer to HEATED OXYGEN SENSOR in Removal & Installation.
  24. Remove the exhaust manifold studs if damaged.
    Fig 11: Removing Exhaust Manifold Studs
    G01969168Courtesy of GENERAL MOTORS CORP.
  25. Clean and Inspect the right exhaust manifold. Refer to EXHAUST MANIFOLD CLEANING AND INSPECTION in Engine Mechanical - 3.8L.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.