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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1411 (ENGINE CONTROL SYSTEM - 4.8L, 5.3L, & 6.0L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - CHASSISINSTALLATION 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 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 Chevrolet TrailBlazer, and 2004 Buick Rainier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel feed or return pipe to the EVAP/fuel hose/pipe assembly.
  2. Install the EVAP/fuel hose/pipe assembly retaining clips.
    3. Fig 1: Locating Fuel Tank Fittings
    GM899732Courtesy of GENERAL MOTORS CORP.
  3. Install the EVAP/fuel hose/pipe assembly to the vehicle.
  4. Remove the caps from the fuel filter and pipes at the fuel tank.
  5. Connect the fuel return pipe and EVAP pipe to the fuel tank pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Connect the fuel feed pipe to the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 2: View Of EVAP/Fuel Hose/Pipes
    GM856643Courtesy of GENERAL MOTORS CORP.
  7. Install the EVAP/fuel hose/pipe bracket to the bellhousing stud.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the EVAP/fuel hose/pipe bracket nut (2).

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    9. Fig 3: Installing EVAP/Fuel Hose/Pipe Assembly Into Retaining Clips
    GM899734Courtesy of GENERAL MOTORS CORP.
  9. Use the following procedure if the vehicle is equipped with 4WD:
    1. Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission.
    2. Raise the transmission to the normal installed height.
    3. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
    4. Remove the transmission jack.
    5. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
    6. Install the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4 or to Transfer Case Assembly Replacement (TrailBlazer, Envoy) in Transfer Case - NVG 226-NP8.
    10. Fig 4: Installing EVAP/Fuel Hose/Pipe Assembly Into Retaining Clips
    GM899733Courtesy of GENERAL MOTORS CORP.
  10. Use the following procedure if the vehicle is equipped with 2WD:
    1. Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission.
    2. Raise the transmission to the normal installed height.
    3. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
    4. Remove the transmission jack.
    11. Fig 5: View Of Right Catalytic Converter To The Exhaust Manifold Connection
    GM899636Courtesy of GENERAL MOTORS CORP.
  11. Install the nuts securing the right catalytic converter to the exhaust manifold.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

    12. Fig 6: View Of Left Catalytic Converter To The Exhaust Manifold Connection
    GM899634Courtesy of GENERAL MOTORS CORP.
  12. Install the nuts securing the left catalytic converter to the exhaust manifold.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

  13. Lower the vehicle.
    14. Fig 7: View Of EVAP/Fuel Hose/Pipes
    GM856643Courtesy of GENERAL MOTORS CORP.
  14. Remove the caps from the fuel rail and EVAP pipes.
  15. Connect the EVAP canister purge pipe (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) 
  16. Connect the fuel feed and return pipes (1) at the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  19. Use the following procedure to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for leaks.
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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.