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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1569 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER OUTLET TUBE REPLACEMENT (6.6L 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 a NEW O-ring seal onto the water outlet.
  2. Lightly lubricate the O-ring seal with coolant.
  3. Install the water outlet.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the water outlet tube bolts.

    Tighten 

    Tighten the bolt to 21 N.m (15 lb ft).

    Fig 1: Installing Water Outlet, Bolts & O-Ring Seal
    G02109111Courtesy of GENERAL MOTORS CORP.
  5. Install the turbocharger bypass valve and washer.

    Tighten 

    Tighten the valve to 60 N.m (44 lb ft).

    Fig 2: Install Turbocharger Bypass Valve & Washer
    G02109112Courtesy of GENERAL MOTORS CORP.
  6. Connect the turbocharger coolant return hose to the turbocharger bypass valve.
    Fig 3: Connect Turbocharger Coolant Return Hose
    G02109113Courtesy of GENERAL MOTORS CORP.
  7. Install the bolt and wiring harness bracket to the thermostat housing.

    Tighten 

    Tighten the bolt to 8 N.m (71 lb in).

    Fig 4: Install Bolt & Wiring Harness Bracket
    G02109114Courtesy of GENERAL MOTORS CORP.
  8. Install the radiator inlet hose to the water outlet tube.
  9. Fill the cooling system. Refer to Draining and Filling Cooling System .
    Fig 5: Install Radiator Inlet Hose
    G02109115Courtesy of GENERAL MOTORS CORP.
  10. Install the upper intake manifold cover.
  11. Install the upper intake manifold cover to the outlet duct.
  12. Tighten the outlet clamp at the upper intake manifold cover.

    Tighten 

    Tighten the clamp to 6 N.m (53 lb in).

    Fig 6: Install Upper Intake Manifold Cover
    G02109116Courtesy 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.