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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 971 (ENGINE CONTROLS - 8.1L (INTRODUCTION))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (CAB/CHASSIS - FRONT)INSTALLATION 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 Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel and EVAP pipes.
    Fig 1: Fuel Tank - Cab/Chassis
    GM1228169Courtesy of GENERAL MOTORS CORP.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    7. Fig 2: Fuel Tank Shield - Cab/Chassis
    GM877744Courtesy of GENERAL MOTORS CORP.
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

  10. Lower the vehicle.
    11. Fig 3: Fuel Feed And EVAP Quick Connect Fittings At The Sending Unit - Cab/Chassis
    GM1228206Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 4: Fuel Sending Unit And Fuel Pressure Sensor Electrical Connectors - Cab/Chassis
    GM1238183Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  13. Install the CVS line to the fuel tank clips.
    14. Fig 5: View Of Fuel Fill Pipe Clamp & Vent Pipe Clamp
    GM1228174Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel fill pipe and vent pipe to the tank.
  15. Tighten the vent pipe clamp (1) at the tank.
  16. Tighten the fuel fill pipe clamp (2) at the tank.

    Tighten:  Tighten the clamps to 2.5 N.m (22 lb in).

    17. Fig 6: View Of Fuel Feed And Pressure Balance Lines
    GM1228187Courtesy of GENERAL MOTORS CORP.
  17. Remove the caps from the fuel feed and EVAP pipes.
  18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  19. Refill the fuel tank.
  20. Install the fuel fill cap.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  22. Perform the following steps in order 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 fuel 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.