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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 636 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSMUFFLER 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 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on underbody to prevent overheating on the floor pan and possible damage to the passenger compartment insulation and trim materials.
  1. Join the muffler and the exhaust pipe together.
  2. Install the muffler clamp. Do not tighten at this time.
    Fig 1: Installing Muffler To Exhaust Pipe
    G01818246Courtesy of GENERAL MOTORS CORP.
  3. Apply a soapy solution to the tail pipe hanger rod and the inner diameter of the rear exhaust hanger in order to ease the installation of the hanger.
  4. Press the rear exhaust hanger over the tail pipe hanger rod.
  5. Position the rear exhaust hanger to the rear exhaust hanger bracket.
    CAUTION: Refer to FASTENER NOTICE .
  6. Install the nut securing the rear exhaust hanger to the rear exhaust hanger bracket.

    Tighten 

    Tighten the rear exhaust hanger nut to 30 N.m (22 ft lbs).

    7. Fig 2: Installing Rear Exhaust Hanger
    G01818247Courtesy of GENERAL MOTORS CORP.
  7. Align the muffler to the vehicle, ensuring the rear tail pipe opening is positioned horizontally.
  8. Tighten the muffler clamp previously installed in step 2.

    Tighten 

    Tighten the muffler clamp nuts to 40 N.m (30 ft lbs).

  9. Lower the vehicle.
RENDER: 1.0x

NO RELATED

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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.