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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 671 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER CROSSOVER REPLACEMENT (8.1L ENGINE)REMOVAL PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Removal Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Removal Procedure
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Inlet Hose Clamp & Water Crossover
    GM751425Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System .
  2. Remove the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT -- ACCESSORY .
  3. Reposition the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
    5. Fig 2: Heater Inlet Hose
    GM750694Courtesy of GENERAL MOTORS CORP.
  5. Reposition the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
    7. Fig 3: Thermostat Bypass Hose & Clamps
    GM470692Courtesy of GENERAL MOTORS CORP.
  7. Reposition the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
    9. Fig 4: View of Generator Bracket Bolts
    GM751458Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator. Refer to GENERATOR (4.8L, 5.3L & 6.0L ENGINES) or GENERATOR (8.1L ENGINE) .
  10. Remove the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (4.8 L, 5.3 L, & 6.0L) or POWER STEERING PUMP REPLACEMENT (8.1 L) .
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
    14. Fig 5: View Of Engine Coolant Crossover & Gasket
    GM470698Courtesy of GENERAL MOTORS CORP.
  14. Remove the water crossover bolts.
  15. Remove the water crossover.
  16. Remove and discard the water crossover gaskets.
    17. Fig 6: View Of Water Outlet, Bolts & Thermostat
    GM635643Courtesy of GENERAL MOTORS CORP.
  17. If replacing the water crossover remove the following:
    1. Water outlet bolts (2)
    2. Water outlet (1)
    3. Thermostat (3)
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.