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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1000 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK REPLACEMENTREMOVAL PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Removal Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Removal Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)  or Draining and Filling Cooling System (without HP2) .
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Control - 4.3 L, Air Cleaner Assembly Replacement in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or Air Cleaner Assembly Replacement in Engine Control - 8.1 L.
  3. Remove the surge tank overflow hose from the surge tank.
    4. Fig 1: View Of Surge Tank & Overflow Hose
    GM659051Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the coolant level sensor electrical connector (3).
    5. Fig 2: View Of Auxiliary Battery Relay, MAF, IAT & Coolant Level Sensor Electrical Connectors
    GM674702Courtesy of GENERAL MOTORS CORP.
  5. Reposition the surge tank inlet and outlet hose clamps.
  6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank.
    7. Fig 3: View Of Surge Tank Outlet Hose & Surge Tank
    GM659059Courtesy of GENERAL MOTORS CORP.
  7. Reposition the surge tank inlet hose clamp from the surge tank.
  8. Remove the surge tank inlet hose (1) from the surge tank.
    9. Fig 4: View Of Surge Tank & Inlet Hose
    GM721988Courtesy of GENERAL MOTORS CORP.
  9. Reposition the surge tank outlet hose clamp from the surge tank.
  10. Remove the surge tank outlet hose (2) from the surge tank.
    11. Fig 5: View Of Surge Tank Outlet Hose & Surge Tank
    GM659059Courtesy of GENERAL MOTORS CORP.
  11. Remove the bolt from the surge tank.
  12. Remove the nut from the surge tank.
  13. Remove the surge tank.
    14. Fig 6: View Of Surge Tank, Nuts & Bolts
    GM362165Courtesy 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.