Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 255 (ENGINE CONTROLS - REMOVAL & INSTALLATION)FUEL SYSTEMS (CNG)FUEL TANKASSEMBLY PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD
Assembly Procedure
2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Assembly Procedure
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
If replacing the tank, install the following components:
- Install the vent boot. Tighten the vent boot clamp to specification. See TORQUE SPECIFICATIONS .
- Install the fuel outlet fitting (1) to the tank valve using a new "O" ring. Lubricate the new "O" ring face seal with petroleum jelly or the equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
- Install the fuel inlet fitting (3) to the tank valve using a new "O" ring. Lubricate the new "O" ring face seal with petroleum jelly or the equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
- Install the FTP sensor (2) using a new "O" ring face seal. Lubricate the new "O" ring with petroleum jelly or the equivalent. Tighten the FTP sensor to specification. See TORQUE SPECIFICATIONS .
- Install the HPL Pressure Relief Device line fitting (4) in the tank valve. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
- Install the new rubber isolators.
- Obtain a new CNG Fuel Only label and a new Bi-fuel Information label.
- Record the new tank service expiration date on each label.
- Install the new labels.
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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.