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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 247 (ENGINE CONTROL SYSTEM - REMOVAL & INSTALLATION)FUEL SYSTEMSFUEL TANKREMOVAL
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Fuel Tank: Removal

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Removal
WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain fuel tank into approved container.
  2. Raise and support vehicle.
  3. Remove catalytic converter and intermediate pipe assembly.
  4. Remove 2 left side bolts (1) and 3 right side bolts (3) from the rear exhaust heat shield (2). See Fig 1 .
  5. Remove rear exhaust heat shield (2) from the underbody.
  6. Remove 2 bolts (1) securing the parking brake cable (2) on left side of vehicle. See Fig 2 .
  7. Remove 2 bolts (1) securing the parking brake cable (2) on right side of vehicle. See Fig 3 .
  8. Disconnect fuel supply line. See QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR)  .
  9. Loosen fuel filler hose clamp (1). See Fig 4 .
  10. Disconnect fuel filler hose (2) from the fuel tank.
  11. Disconnect filler pipe vent line (1) from fuel tank (2). See Fig 5 .
  12. Disconnect the On-Board Refueling Vapor Recovery (ORVR) vent line (1) from the Fill Limiter Vent Valve (FLVV) by pinching both sides of the hose connector. See Fig 6 .
  13. Disconnect the filler pipe vent line (1) from the FLVV (2). See Fig 7 .
  14. Disconnect EVAP vapor line (1) from the EVAP canister by pinching both sides of the hose connector. See Fig 8 .
  15. Support the fuel tank with a transmission jack or other suitable fixture.
  16. Remove 4 bolts (1) and the 2 fuel tank straps (2). See Fig 9 .
  17. Remove fuel tank (3).
  18. If replacing the fuel tank, remove all lines, hoses, and the FLVV, and install on the replacement fuel tank.
Fig 1: Removing Rear Exhaust Heat Shield
G00180626Courtesy 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.