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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1288 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT (AWD)INSTALLATION PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Installation Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE .
  1. Install the lower heat insulator.
  2. Install the lower heat insulator bolts.
    1. Tighten 
    2. Tighten the lower heat insulator bolts to 12 N.m (9 lb ft).
  3. Install the following components:
    • The exhaust manifold gasket
    • The exhaust manifold
  4. Install the 2 exhaust manifold nuts (1) and 3 exhaust manifold bolts (2).
    1. Tighten 
    2. Tighten the exhaust manifold nuts and bolts to 37 N.m (27 lb ft).
  5. Install the upper heat insulator.
  6. Install the upper heat insulator bolts.
    1. Tighten 
    2. Tighten the upper heat insulator bolts to 18 N.m (13 lb ft).
      Fig 1: Installing 2 Exhaust Manifold Nuts (1) And 3 Exhaust Manifold Bolts (2)
      G01548136Courtesy of GENERAL MOTORS CORP.
  7. Install 1 bolt (1) to the manifold support bracket to exhaust manifold.
    1. Tighten 
    2. Tighten the exhaust manifold support bracket bolt to 49 N.m (37 lb ft).
      Fig 2: Installing 1 Bolt (1) To Manifold Support Bracket To Exhaust Manifold
      G01548137Courtesy of GENERAL MOTORS CORP.
  8. Install the exhaust manifold flange gasket.
  9. Install the following components to the exhaust manifold flange:
    • The springs
    • 2 bolts
      1. Tighten 
      2. Tighten the exhaust manifold flange bolts to 43 N.m (32 lb ft).
  10. Install the exhaust pipe hanger (2).
  11. Install the Heated Oxygen Sensor (HO2S1) (1). Refer to HEATED OXYGEN SENSOR 1 or HEATED OXYGEN SENSOR 1 in Engine Controls - 1.8L (LV6).
  12. Lower the vehicle.
    CAUTION: Refer to BATTERY DISCONNECT CAUTION .
  13. Connect the negative battery cable.
    Fig 3: Installing Exhaust Pipe Hanger (2) And Heated Oxygen Sensor (HO2S1) (1)
    G01548138Courtesy of GENERAL MOTORS CORP.
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.