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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1732 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT (8.1L 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 a NEW exhaust manifold gasket.
  2. Install the exhaust manifold.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the exhaust manifold bolt and nuts.

    Tighten 

    • Tighten the bolt to 35 N.m (26 lb ft).
    • Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise and suitably support the vehicle with safety stands.
    Fig 1: Installing Exhaust Manifold, Gasket, Bolt & Nuts - Right (8.1L)
    G02133505Courtesy of GENERAL MOTORS CORP.
  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts and nuts.

    Tighten 

    Tighten the bolts/nuts to 25 N.m (18 lb ft).

  7. Lower the vehicle.
    Fig 2: Installing Exhaust Manifold Heat Shield, Bolts & Nuts - Right (8.1L)
    G02133506Courtesy of GENERAL MOTORS CORP.
  8. Position the EGR pipe.
  9. Install a NEW EGR pipe gasket (1).
  10. Install the EGR pipe bracket bolt (4).

    Tighten 

    Tighten the bolt to 50 N.m (37 lb ft).

  11. Install the EGR pipe nuts (5) to the exhaust manifold.

    Tighten 

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

  12. Install the spark plugs. Refer to SPARK PLUG .
    Fig 3: Installing EGR Pipe Gasket, Bracket Bolt & Nuts (8.1L)
    G02133507Courtesy of GENERAL MOTORS CORP.

    Important:  Fully install the spark plug wires by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

  13. Install the spark plug wires to the spark plugs and ignition coils.
  14. Install the oil level indicator.
  15. Install the wheelhouse panel. Refer to WHEELHOUSE PANEL REPLACEMENT in Body Front End.
    Fig 4: Installing Spark Plug Wires - Right (8.1L)
    G02133508Courtesy 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.