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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 361 (ENGINE CONTROLS - REMOVAL & INSTALLATION, OVERHAUL)FUEL SYSTEMSFUEL TANKS (WITHOUT FEEDBACK FUEL SYSTEM)INSTALLATION
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Fuel Tanks (Without Feedback Fuel System): Installation

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Installation
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When replacing the fuel system hose clamps, always replace the clamps with the original equipment or parts that meet the GM specifications.
  1. Install the fuel tank. Install the fuel tank strap. Install the fuel tank strap bolts and tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove the cap from the EVAP pipe.
  2. Connect the EVAP pipe quick-connect fitting at the left fuel tank EVAP pipe. See FUEL LINE DISCONNECT FITTINGS . Install the tank crossover hose. Push the clamp outboard against the fuel tank keeping the clamp parallel with the White stripe on the tank crossover hose. Tighten the tank crossover hose clamp to specification.
  3. Remove the caps from the fuel pipes. Connect the auxiliary fuel return rear pipe, the fuel return rear pipe, and the fuel feed rear pipe to the fuel sender. See Figure. Connect the fuel sender electrical connector. On A/T models, install the left muffler.
  4. On all models, install the fuel tank shield. Install the fuel tank shield mount bolt and nut and tighten to specification. Connect the fuel fill hose and the vent pipe. Tighten the fuel fill hose clamp to specification. Install the left rear wheelhouse panel. See TORQUE SPECIFICATIONS . Install the left rear tire and wheel. Tighten wheel lug nuts to specification.
  5. Lower the vehicle. Refill the fuel system. Connect the negative battery cable. Perform the following in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.
  6. Check if keyless entry transmitters function properly. If battery was disconnected, transmitter may not communicate or may loose synchronization with the receiver. If transmitters do not function properly, reprogram transmitters. See KEYLESS ENTRY TRANSMITTER SYNCHRONIZATION  under PROGRAMMING.


NOTE: When replacing the fuel system hose clamps, always replace the clamps with the original equipment or parts that meet the GM specifications.
  1. Install the fuel tank. Install the fuel tank strap. Install the fuel tank strap bolts and tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove the cap from the EVAP pipe.
  2. Connect the EVAP pipe quick-connect fitting at the right fuel tank EVAP pipe. See FUEL LINE DISCONNECT FITTINGS . Install the fuel tank crossover hose. Push the clamp outboard against the fuel tank keeping the clamp parallel with the White stripe on the tank crossover hose. Tighten the fuel tank crossover hose clamp to specification.
  3. Connect the fuel pressure sensor electrical connector. Connect the vent hose to the EVAP canister. Install the EVAP canister access cover. Install the right rear wheelhouse panel. Remove the caps from the fuel pipes. Connect the auxiliary fuel return rear pipe and auxiliary fuel feed rear pipe to the fuel sender.
  4. Connect the fuel sender electrical connector. On A/T models, install the right muffler. On all models, install the fuel tank shield. Install the fuel tank shield mount bolt and nut and tighten to specification. See TORQUE SPECIFICATIONS . Install the right rear tire and wheel. Tighten wheel lug nuts to specification.
  5. Lower the vehicle. Refill the fuel system. Connect the negative battery cable. Perform the following in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.
  6. Check if keyless entry transmitters function properly. If battery was disconnected, transmitter may not communicate or may loose synchronization with the receiver. If transmitters do not function properly, reprogram transmitters. See KEYLESS ENTRY TRANSMITTER SYNCHRONIZATION  under PROGRAMMING.
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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.