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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 593 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER CROSSOVER REPLACEMENT (8.1L)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 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostat with the seal into the coolant crossover.
  2. Install the water outlet bolts.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  3. Install the water outlet bolts.

    Tighten 

    Tighten the water outlet bolts to 30 N.m (22 ft lbs).

  4. Place the coolant crossover gaskets and the coolant crossover in position.
  5. Install the coolant crossover bolts.

    Tighten 

    Tighten the coolant crossover bolts to 50 N.m (37 ft lbs).

    Fig 1: Installing Thermostat & Coolant Crossover Bolts
    G01699563Courtesy of GENERAL MOTORS CORP.
  6. Install the thermostat bypass hose clamps onto the thermostat bypass hose.
  7. Install the thermostat bypass hose.

    Important:  Properly position the bypass hose clamps to avoid water pump pulley interference.

  8. Position the thermostat bypass hose clamps.
    Fig 2: Installing Thermostat Bypass Hose
    G01699564Courtesy of GENERAL MOTORS CORP.
  9. Install the drive belt tensioner.
  10. Install the drive belt tensioner bolts.

    Tighten 

    Tighten the drive bolt tensioner bolts to 50 N.m (37 ft lbs).

  11. Refill the cooling system. Refer to Draining and Filling Cooling System .
    Fig 3: Installing Drive Belt Tensioner
    G01699565Courtesy 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.