Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 638 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK 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 2002 Oldsmobile Aurora and 2001 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.

Install the surge tank outlet hose to the surge tank.
Using the J 37097-A reposition the clamp.

Fig 1: Identifying Surge Tank
Courtesy of GENERAL MOTORS CORP.
Position the surge tank (1) over the 2 studs at the wheelhouse.
CAUTION: Refer to FASTENER NOTICE .
Install the surge tank fasteners and push nut (3).
Tighten

Tighten the surge tank nut (2) and bolt to 6 N.m (53 in lbs).
Connect the coolant level sensor electrical connection.

Fig 2: Connecting Surge Tank Mounting
Courtesy of GENERAL MOTORS CORP.
Install the secondary AIR relay bracket (1) over the studs.
Install the 2 secondary AIR relay bracket nuts (2).
Tighten

Tighten the secondary AIR relay bracket nuts (2) to 6 N.m (53 in lbs).

Fig 3: Installing Secondary AIR Relay Bracket
Courtesy of GENERAL MOTORS CORP.
Connect the surge tank inlet hose to the surge tank.
Fill the cooling system. Refer to Draining and Filling Cooling System .

Fig 4: Connecting Surge tank Inlet Hose
Courtesy 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.