Exhaust Manifold Removal - Right Side C/K/C3500HD

1. Remove the secondary air injection pipe nut from the fuel injection fuel rail stud (if applicable).
2. Remove the secondary air injection pipe bolts from the right exhaust manifold (if applicable).
3. Disconnect the secondary air injection pipe from the secondary air injection pump pipe (if applicable).
4. Remove the secondary air injection pipe (if applicable).



5. Remove the secondary air injection pump pipe bolt from the right cylinder head (if applicable).
6. Remove the secondary air injection pump pipe (if applicable).




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 wire.

7. Remove the right spark plug wires from the spark plugs and ignition coils.



8. Remove the exhaust gas recirculation (EGR) pipe bolts from the EGR adapter plate.
9. Remove the EGR pipe nuts from the right exhaust manifold.
10. Remove the EGR pipe bracket bolt.
11. Remove the EGR pipe and gaskets.



12. Remove the right exhaust manifold heat shield bolts and nuts.
13. Remove the right exhaust manifold heat shield.



14. Remove the right exhaust manifold nuts and center bolt.
15. Remove the right exhaust manifold.
16. Remove the right exhaust manifold gasket.



17. Remove the right spark plugs.



18. Remove the exhaust manifold studs, if necessary.

Exhaust Manifold Removal - Right Side G

1. Remove the secondary air injection pump pipe nut from the fuel injection fuel rail stud (if applicable).
2. Remove the secondary air injection pump pipe bolt from the right cylinder head (if applicable).
3. Disconnect the secondary air injection pipe from the secondary air injection pump pipe (if applicable).
4. Remove the secondary air injection pump pipe (if applicable).



5. Remove the secondary air injection pipe bolts from the right exhaust manifold (if applicable).
6. Remove the secondary air injection pipe (if applicable).




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 wire.

7. Remove the right spark plug wires from the spark plugs and ignition coils.



8. Remove the exhaust gas recirculation (EGR) pipe bolts from the EGR valve.
9. Remove the EGR pipe nuts from the right exhaust manifold.
10. Remove the EGR pipe bracket bolt.
11. Remove the EGR pipe and gaskets.



12. Remove the right exhaust manifold heat shield bolts and nuts.
13. Remove the right exhaust manifold heat shield.



14. Remove the right exhaust manifold nuts and center bolt.
15. Remove the right exhaust manifold.
16. Remove the right exhaust manifold gasket.



17. Remove the right spark plugs.



18. Remove the exhaust manifold studs, if necessary.

Exhaust Manifold Removal - Right Side Medium Duty

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 wire.

1. Remove the right spark plug wires from the spark plugs and ignition coils.



2. Remove the exhaust gas recirculation (EGR) pipe bolts from the EGR adapter.
3. Remove the EGR pipe nuts from the right exhaust manifold.
4. Remove the EGR pipe bracket bolt.
5. Remove the EGR pipe and gaskets.



6. Remove the right exhaust manifold heat shield nuts.
7. Remove the right exhaust manifold heat shield.



8. Remove the right exhaust manifold nuts and center bolt.
9. Remove the right exhaust manifold.
10. Remove the right exhaust manifold gasket.



11. Remove the right spark plugs.



12. Remove the exhaust manifold studs, if necessary.