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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1628 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L)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 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new exhaust manifold gasket.
  2. Install the exhaust manifold.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the exhaust manifold bolts and the nuts.

    Tighten 

    Tighten the bolts and the nuts to 30 N.m (22 lb ft).

    Fig 1: Installing Exhaust Manifold, Gasket, Bolts & Nuts
    G01969140Courtesy of GENERAL MOTORS CORP.
  4. Install the exhaust manifold heat shield.
    Fig 2: Installing Exhaust Manifold Heat Shield & Nuts
    G01969141Courtesy of GENERAL MOTORS CORP.
  5. Install the exhaust manifold heat shield nuts.

    Tighten 

    Tighten the nuts to 20 N.m (15 lb ft).

  6. Install the engine lift bracket.
    Fig 3: Installing Engine Lift Bracket & Nut
    G01969142Courtesy of GENERAL MOTORS CORP.
  7. Install the engine lift bracket bolt and the nut.

    Tighten 

    Tighten the bolt and the nut to 30 N.m (22 lb ft).

  8. Install the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE REPLACEMENT in Engine Mechanical - 3.8L.
  9. Install the left spark plugs to cylinders 1, 3 and 5. Refer to SPARK PLUGS in Self-Diagnostics - 3.8L.
  10. Install the exhaust crossover bolts to the left exhaust manifold.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

    Fig 4: Installing Exhaust Crossover Bolts
    G01969143Courtesy of GENERAL MOTORS CORP.
  11. Install the lower right engine mount strut bracket. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT LOWER in Engine Mechanical - 3.8L.
  12. Install the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT and ENGINE MOUNT STRUT REPLACEMENT - LEFT in Engine Mechanical - 3.8L.
  13. Install 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.
  14. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
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.