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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 818 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK REPLACEMENTREMOVAL 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 8 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Yukon, 2003 Chevrolet Tahoe, 2003 Chevrolet Suburban, and 2003 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
  2. Remove the air cleaner assembly.
  3. Remove the surge tank overflow hose from the surge tank.
    Fig 1: Removing Surge Tank Overflow Hose From Surge Tank
    G02117657Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the low coolant level switch electrical connector (3).
    Fig 2: Disconnecting Low Coolant Level Switch Electrical Connector
    G02117658Courtesy of GENERAL MOTORS CORP.
  5. Reposition the surge tank inlet hose clamp.
  6. Remove the surge tank inlet (1) hose from the surge tank.
    Fig 3: Removing Surge Tank Inlet Hose From Surge Tank
    G02117659Courtesy of GENERAL MOTORS CORP.
  7. Reposition the surge tank outlet hose clamp.
  8. Remove the surge tank outlet hose (2) from the surge tank.
    Fig 4: Removing Surge Tank Outlet Hose From Surge Tank
    G02117660Courtesy of GENERAL MOTORS CORP.
  9. Remove the bolt from the surge tank.
  10. Remove the nut from the surge tank.
  11. Remove the surge tank.
    Fig 5: Removing Surge Tank
    G02117661Courtesy 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.