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Chevrolet Trailblazer 2002-2009 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Trailblazer Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Generation Generation Name: GMT360/370 Generation Years: 2002-2009 Codes Platform Code: GMT360...
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Chevrolet Trailblazer 2002-2009 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Trailblazer
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Generation
Generation Name:
GMT360/370
Generation Years:
2002-2009
Codes
Platform Code:
GMT360 (for 2WD) / GMT370 (for 4WD)
👋 Introduction
Market Position
Positioning:
The Chevrolet Trailblazer, during its production run, occupied a significant segment of the mid-size SUV market, known for its truck-like capability and available V8 power, often appealing to families and those needing towing capacity.
Competitive Analysis
Competitors:
Ford Explorer, Jeep Grand Cherokee, Dodge Durango, Toyota 4Runner, Nissan Pathfinder.
Key Features
Vehicle Strengths:
Strong V8 engine options (5.3L, 6.0L), robust towing capacity, available off-road packages (Z71), generally comfortable ride for a body-on-frame SUV, relatively spacious interior.
Manual Value Proposition:
Provides factory-level diagnostic and repair information, enabling owners and independent technicians to perform a wide range of services accurately and efficiently, saving time and money compared to dealership service.
📋 Manual Details
Coverage Areas
Global Coverage:
North America (primarily)
Specific Models Covered:
Chevrolet Trailblazer (2002-2009), including various trim levels and configurations.
Page Count
Estimated Pages:
10000+
Manual Type
Type:
Factory Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical (4.2L Atlas I6, 5.3L Vortec V8, 6.0L Vortec V8), Engine Cooling, Engine Electrical, Engine Control (4.2L, 5.3L), Automatic Transmission (4L60-E, 4L70-E), Transfer Case (NVG 126, NVG 226)
Chassis:
Front Suspension, Rear Suspension, Front Drive Axle, Rear Drive Axle, Drive Axles, Wheel Drive Shafts, Propeller Shaft, Disc Brakes, Hydraulic Brakes, Antilock Brakes (ABS), Park Brake, Power Steering, Steering Wheel and Column, Air Suspension
Body:
Body Front End, Body Rear End, Doors, Exterior Trim, Interior Trim, Roof, Seats, Stationary Windows, Sunroof, Bumpers, Frames, Frame and Underbody, Lifting Points, Mirrors
Electrical And Electronics:
Engine Electrical, Fuses and Circuit Breakers, Lighting System, Horns, HVAC, Instrument Panel, Gages and Panels, Entertainment, Navigation, Keyless Entry, Airbags, Restraint System, Cruise Control, Shift Lock Control, Service Reminder Indicator, Tire Pressure Monitor, Electrical Component Locations
Body Control Modules:
Detailed information on Body Control Module (BCM) functions and diagnostics for various features.
Procedures Included
Maintenance:
Scheduled Maintenance, Lubrication, Fluid Checks and Replacements, Filter Replacements, Belt Inspections and Replacements
Diagnostics And Troubleshooting:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), System-Specific Diagnostics, Wiring Diagrams for all systems
Repair And Rebuild:
Detailed step-by-step repair procedures for all major components and systems, including engine, transmission, differentials, brakes, suspension, steering, and body components.
Special Procedures:
Airbag system service precautions, HVAC system refrigerant handling, Transfer case service procedures (NVG 126/226), Differential service (locking and trucks).
Wiring Diagrams:
Comprehensive, system-specific wiring diagrams for electrical troubleshooting.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all Windows and Mac computers (Windows 10, 8, 7, Vista, XP, ME, 98, NT, 2000), Tablets, and Phones. Supports 32/64-bit operating systems.
Print Quality
Resolution:
Hi-Resolution illustrations, photos, and diagrams.
Binding Type
Binding:
Digital (Downloadable PDF)
Paper Type
Paper Type Equivalent:
N/A (Digital format allows for unlimited printing)
⚙️ Engine Specifications
Primary Engine
Engine 4 2L Atlas I6:
4.2L (256 cu in) Atlas I6, DOHC, 24-valve. Power: approx. 275-291 hp. Torque: approx. 275-295 lb-ft.
Engine 5 3L Vortec V8:
5.3L (323 cu in) Vortec V8 (LM4/LM7), OHV, 16-valve, Active Fuel Management (AFM) on later models. Power: approx. 285-300 hp. Torque: approx. 320-325 lb-ft.
Engine 6 0L Vortec V8:
6.0L (364 cu in) Vortec V8 (LQ4/LQ9), OHV, 16-valve. Power: approx. 300-345 hp. Torque: approx. 360-370 lb-ft. Primarily in SS and performance trims.
Performance
0 60 Mph Est:
Varies by engine and drivetrain, generally 7-9 seconds for V8 models.
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPFI)
Fuel Type:
Unleaded gasoline (87 octane recommended for I6 and 5.3L V8, premium may be beneficial for 6.0L)
Maintenance Items
Spark Plugs 4 2L I6:
ACDelco Professional Iridium (e.g., 41-104, check manual for exact spec)
Spark Plugs 5 3L V8:
ACDelco Professional Iridium (e.g., 41-103, check manual for exact spec)
Oil Capacity 4 2L I6:
Approx. 7 U.S. quarts (6.6 liters) with filter change.
Oil Capacity 5 3L V8:
Approx. 7 U.S. quarts (6.6 liters) with filter change.
Oil Type 4 2L I6:
SAE 5W-30 Synthetic Blend or Full Synthetic (API SN or later).
Oil Type 5 3L V8:
SAE 5W-30 Synthetic Blend or Full Synthetic (API SN or later, 5W-30 Dexos1 recommended for AFM engines).
Coolant Capacity:
Approx. 15 U.S. quarts (14.2 liters)
🔧 Transmission
Standard
Transmission I6:
4-speed automatic 4L60-E
Transmission V8:
4-speed automatic 4L60-E (for 5.3L), 4-speed automatic 4L70-E (heavy-duty version for 5.3L/6.0L)
Optional
Optional Transmissions:
N/A (Automatics were standard for the model range)
Features
Transmission Features:
Electronic control, Tow/Haul mode, Lock-up torque converter.
Fluid Specifications
Transmission Fluid Type:
Dexron-III H (or Dexron-VI for later models, consult specific vehicle manual).
Fluid Capacity
Transmission Fluid Capacity:
Approx. 6.5 U.S. quarts (6.2 liters) for a fluid and filter change.
📐 Dimensions
Exterior
Wheelbase:
113 inches (2,870 mm)
Length:
Approx. 192-194 inches (4,877-4,928 mm)
Width:
Approx. 73-74 inches (1,854-1,880 mm)
Height:
Approx. 73-74 inches (1,854-1,880 mm)
Weights
Curb Weight:
Approx. 4,500 - 5,000 lbs (2,041 - 2,268 kg) depending on configuration.
Towing Capacity:
Up to 6,600 lbs (2,994 kg) with appropriate towing package and engine.
Cargo
Cargo Volume Behind 1St Row:
Approx. 80.1 cu ft (2,268 liters)
Cargo Volume Behind 2Nd Row:
Approx. 40.7 cu ft (1,153 liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars (for models equipped with side curtain airbags)
NHTSA Front Impact Passenger:
5 Stars (for models equipped with side curtain airbags)
IIHS Frontal Offset:
Good (for most model years, but check specific reports)
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Traction Control System (TCS), available StabiliTrak electronic stability control (later models).
Passive Features
Passive Safety Features:
Front airbags, available front side-impact airbags, available roof-rail/curtain airbags, three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Infotainment Systems:
Available premium audio systems, CD player, optional navigation system on later models. Basic AM/FM radio with cassette or CD player standard.
Driver Assistance
Driver Assistance Features:
Available rear parking assist (on some models), Tire Pressure Monitoring System (TPMS), StabiliTrak electronic stability control (on later models).
Connectivity
Connectivity Options:
Keyless entry, available OnStar telematics system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (with synthetic oil). Check manual for specific recommendations.
Tire Rotation:
Every 7,500 miles (or with oil change).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).
Cabin Air Filter:
Replace every 15,000-30,000 miles, depending on driving conditions.
Transmission Fluid Change:
Every 50,000-100,000 miles, depending on usage and fluid condition. Consult manual for specific intervals.
Fluid Specifications
Coolant Type:
GM Original Equipment (OE) Dex-Cool coolant (Orange) or equivalent silicate-free, extended-life coolant.
Brake Fluid Type:
DOT 3
Power Steering Fluid Type:
GM Power Steering Fluid (P/N 12345899) or Dexron-III H automatic transmission fluid.
Known Issues
Common Problems:
Brake wear (especially rear brakes), front suspension component wear (ball joints, tie rods), fuel pump failure, ignition coil issues, transmission cooler line leaks, potential head gasket issues on some V8 engines, water pump leaks, HVAC blower motor issues.
📚 Vehicle History
Brand Heritage
Chevrolet SUV Lineage:
Chevrolet has a long history of SUVs, starting with models like the K5 Blazer and Tahoe. The Trailblazer represented a more modern, unibody-based (though the Trailblazer was body-on-frame based on the GMT360 platform) approach to the mid-size SUV, offering a blend of utility and comfort.
Model Evolution
Trailblazer Development:
The Trailblazer was introduced for the 2002 model year as the upscale variant of the Chevrolet's mid-size SUV lineup, which also included the GMC Envoy and Oldsmobile Bravada (discontinued after 2004), Buick Rainier, Isuzu Ascender, and Saab 9-7X. It was designed to compete in the growing mid-size SUV segment and was initially praised for its refined ride and powerful engine options.
Key Updates:
Introduction of the 5.3L V8 engine in 2003, optional third-row seating, introduction of the higher-performance SS model with the 6.0L V8 in 2006, introduction of Active Fuel Management (AFM) on the 5.3L V8 in 2007, minor styling updates throughout the generation.
Production
Production Location:
Moraine, Ohio, USA (GM's Moraine Assembly Plant)
Production End Date:
The Moraine Assembly Plant closed in 2008, effectively ending production of the Trailblazer in North America, though some minor markets may have received later models.
🏆 Awards & Recognition
Recognitions
Past Awards:
The Trailblazer's platform (GMT360) was recognized for its robust design and capabilities, often appearing on "Best Buy" lists or receiving positive reviews in automotive publications during its initial years, particularly for its V8 performance and towing ability.
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