SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1411 (ENGINE CONTROL SYSTEM - 4.8L, 5.3L, & 6.0L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL RAIL CROSSOVER PIPE 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 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.
    Fig 1: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
  2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
  3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15).
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    4. IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
  4. Install the crossover fuel pipe retainer clip (21). Loosely install the retainer clip attaching screw (22).
  5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
  6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
    IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retainer clip attaching screw (4).

    Tighten: 

    1. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in).
    2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).

  10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
    11. Fig 2: View Of EVAP/Fuel Hose/Pipes
    GM856643Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel feed and return pipes (1) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  12. Install the fuel fill cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn OFF the ignition OFF for 10 seconds.
    3. Turn ON the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.