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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1241 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR 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 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the radiator to the lower mounts.
    Fig 1: Installing Radiator Hose
    G02084084Courtesy of GENERAL MOTORS CORP.
  2. Install the transaxle oil cooler pipes.

    Important:  Install new retaining rings into the quick connect fittings.

  3. Ensure the following procedures are performed when installing the new retaining ring onto the fitting.
    Fig 2: Installing Transaxle Oil Cooler Pipes
    G02084085Courtesy of GENERAL MOTORS CORP.
  4. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
    Fig 3: Installing Retaining Ring
    G02084086Courtesy of GENERAL MOTORS CORP.
  5. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
    Fig 4: Rotating Retaining Ring Around Fitting
    G02084087Courtesy of GENERAL MOTORS CORP.

    Important:  DO NOT Push the new retaining ring onto the fitting.

  6. Installing the retaining ring on to the fitting this way will bend the retaining ring.
    Fig 5: Locating Safety Precaution
    G02084088Courtesy of GENERAL MOTORS CORP.
  7. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
    Fig 6: Checking Retaining Ring Moves Freely In Fitting Slots
    G02084089Courtesy of GENERAL MOTORS CORP.
  8. Install the transaxle oil cooler pipes into the radiator quick connect fitting.
    Fig 7: Installing Transaxle Oil Cooler Pipes
    G02084090Courtesy of GENERAL MOTORS CORP.
  9. Insert the transaxle oil cooler pipe ends into the quick connect fitting until you hear or feel a click.
    Fig 8: Inserting Transaxle Oil Cooler Pipe Ends Into Quick Connect Fitting
    G02084091Courtesy of GENERAL MOTORS CORP.
  10. Do not use the plastic cap on the transaxle oil cooler pipe in order to install the transaxle oil cooler pipe into the fitting.
  11. Pull back sharply on the transaxle oil cooler pipe in order to ensure that the transaxle oil cooler pipe is fastened into the quick connect fitting.
    Fig 9: Installing Transaxle Oil Cooler Pipe Into Fitting
    G02084092Courtesy of GENERAL MOTORS CORP.
  12. Position the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
  13. Fully seat the plastic cap against the fitting.
    Fig 10: Positioning Plastic Cap Onto Fitting
    G02084093Courtesy of GENERAL MOTORS CORP.
  14. Allow no gap between the cap and the fitting.
    Fig 11: Identifying No Gap Between Cap And Fitting
    G02084094Courtesy of GENERAL MOTORS CORP.
  15. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating.
    NOTE: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.
  16. Adjust the fluid level.
  17. Raise and support the vehicle. Refer to JACKING AND LIFTING in General Information.
  18. Install the radiator outlet hose to the radiator.
  19. Use the J 38185  in order to reposition the hose clamp to the radiator outlet hose.
  20. Install the lower air deflector. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT - LOWER  .
  21. Lower the vehicle.
  22. Install the radiator inlet hose to the radiator.
  23. Use the J 38185  in order to reposition the hose clamp to the radiator inlet hose.
    Fig 12: Indicating Proper Joint Seating
    G02084095Courtesy of GENERAL MOTORS CORP.
  24. Install the upper radiator brackets.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  25. Install the upper radiator bracket bolts.

    Tighten 

    Tighten the bolts to 24 N.m (18 lb ft).

  26. Install the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC  .
  27. Install the battery. Refer to BATTERY REPLACEMENT in Engine Electrical.
  28. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
    Fig 13: Installing Upper Radiator Brackets
    G02084096Courtesy 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.