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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1569 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER CROSSOVER REPLACEMENT (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.
NOTE: Refer to FASTENER NOTICE .
  1. If replacing the water crossover install the following:
    1. 1.1. Thermostat (3)
    2. 1.2. Water outlet (1)
    3. 1.3. Water outlet bolts (2)

      Tighten 

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

    Fig 1: Install Thermostat, Water Outlet & Bolts
    G02109174Courtesy of GENERAL MOTORS CORP.
  2. Install NEW water crossover gaskets.
  3. Install the water crossover.
  4. Install the water crossover bolts.

    Tighten 

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

    Fig 2: Install Water Crossover, Gaskets & Bolts
    G02109175Courtesy of GENERAL MOTORS CORP.
  5. Install the generator bracket.
  6. Install the generator bracket stud.

    Tighten 

    Tighten the stud to 20 N.m (15 lb ft).

  7. Install the generator bracket bolts and nut.

    Tighten 

    Tighten the bolts and nut to 50 N.m (37 lb ft).

  8. Install the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (6.6 L DIESEL or  POWER STEERING PUMP REPLACEMENT (4.3 L)  or  POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L AND 6.0L)  or  POWER STEERING PUMP REPLACEMENT (8.1L)  .
    Fig 3: Install Generator Bracket, Studs, Bolts & Nuts
    G02109176Courtesy of GENERAL MOTORS CORP.
  9. Install the generator. Refer to GENERATOR (4.3L ENGINE) or  GENERATOR (4.8L, 5.3L & 6.0L ENGINES)  or  GENERATOR (6.6L ENGINE)  or  GENERATOR (8.1L ENGINE)  .
  10. Install the bypass hose.
  11. Position the bypass hose clamps at the water crossover and water pump.
    Fig 4: Install Bypass Hose
    G02109177Courtesy of GENERAL MOTORS CORP.
  12. Install the heater inlet hose to the water crossover.
  13. Position the heater inlet hose clamp at the water crossover.
    Fig 5: Install Heater Inlet Hose
    G02109178Courtesy of GENERAL MOTORS CORP.
  14. Install the inlet hose to the water crossover.
  15. Position the inlet hose clamp at the water crossover.
  16. Install the drive belt tensioner.
  17. Fill the cooling system. Refer to Draining and Filling Cooling System .
    Fig 6: Install Inlet Hose
    G02109179Courtesy of GENERAL MOTORS CORP.
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.