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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1732 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - LEFT (6.6L ENGINE)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 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the exhaust manifold with gasket.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the exhaust manifold bolts/nuts.
    Fig 1: Installing Exhaust Manifold, Gasket, Bolts & Nuts - Left (6.6L)
    G02133459Courtesy of GENERAL MOTORS CORP.
  3. Use the sequence shown, to properly tighten the exhaust manifold bolts.

    Tighten 

    1. 3.1. Tighten the bolts/nut a first pass to 34 N.m (25 lb ft).
    2. 3.2. Tighten the bolts/nuts a final pass to 34 N.m (25 lb ft).
    Fig 2: Exhaust Manifold Bolts Tightening Sequence - Left (6.6L)
    G02133460Courtesy of GENERAL MOTORS CORP.
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts.

    Tighten 

    Tighten the bolts to 8 N.m (71 lb in).

    Fig 3: Installing Exhaust Manifold Heat Shield & Bolts - Left (6.6L)
    G02133461Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  7. Install the exhaust pipe and the bolts (2) to the exhaust manifold.

    Tighten 

    Tighten the bolts to 53 N.m (39 lb ft).

    Fig 4: Installing Exhaust Pipe & Bolts - Left (6.6L)
    G02133462Courtesy of GENERAL MOTORS CORP.
  8. Raise the vehicle.
  9. Install the exhaust pipe heat shield bolts.

    Tighten 

    Tighten the bolts to 8 N.m (71 lb in).

  10. Install the charged air cooler outlet duct.
  11. Install the wheelhouse panel. Refer to WHEELHOUSE PANEL REPLACEMENT in Body Front End.
  12. Install the front tire and wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  13. Lower the vehicle.
    Fig 5: Installing Exhaust Pipe Heat Shield Bolts - Left (6.6L)
    G02133463Courtesy 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.