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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1720 (ENGINE EXHAUST)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENTINSTALLATION 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 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Manifold Gasket
    GM949143Courtesy of GENERAL MOTORS CORP.
  1. Install a new manifold gasket on the cylinder head.
    2. Fig 2: View Of Exhaust Manifold & Gasket
    GM746061Courtesy of GENERAL MOTORS CORP.
  2. Install the exhaust manifold.
    3. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold-to-cylinder head nuts L61 to 18 N.m (13 lb ft).

  4. If necessary, transfer the O2 sensor from the old manifold.
    5. IMPORTANT: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as Permatex® 77124, SA P/N 21485279 or equivalent.
  5. Install the O2 sensor into the exhaust manifold.

    Tighten:  Tighten the O2 sensor to 45 N.m (33 lb ft).

    6. Fig 3: Gasket & Exhaust Pipe
    GM926819Courtesy of GENERAL MOTORS CORP.
  6. Install the gasket and exhaust pipe to the intermediate pipe.
  7. Install the exhaust pipe-to-intermediate pipe nuts.

    Tighten:  Tighten the exhaust pipe-to-intermediate pipe nuts L61 to 30 N.m (22 lb ft).

  8. Attach the rear O2 sensor wire to the heat shield.
    9. Fig 4: Exhaust Manifold Gasket
    GM898154Courtesy of GENERAL MOTORS CORP.
  9. Install a new exhaust manifold gasket onto the exhaust manifold flange studs.
  10. Position the exhaust manifold pipe onto the exhaust manifold studs and install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold pipe-to-exhaust manifold nuts L61 to 42 N.m (31 lb ft).

    11. Fig 5: Exhaust Manifold Heat Shield (2.2L)
    GM951395Courtesy of GENERAL MOTORS CORP.
  11. Lower the vehicle.
  12. Install the exhaust manifold heat shield.
  13. Install the exhaust manifold heat shield bolts.

    Tighten:  Tighten the exhaust manifold heat shield bolts L61 to 23 N.m (17 lb ft).

    14. Fig 6: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  14. Install the outlet resonator/duct assembly into position.
  15. Connect the PVC fresh air vent hose assembly.
  16. Tighten the clamp at the throttle body assembly.
  17. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
  18. Tighten the air cleaner assembly.
  19. Connect the intake air temperature (IAT) sensor connector.
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.