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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)REMOVAL PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Removal Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Removal 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.
IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
    Fig 1: View Of Fuel Feed And Pressure Balance Lines
    GM1228187Courtesy of GENERAL MOTORS CORP.
  2. If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP (evaporative emission ) quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
    4. Fig 2: View Of Fuel Fill Pipe Clamp & Vent Pipe Clamp
    GM1228174Courtesy of GENERAL MOTORS CORP.
  4. Loosen the fuel fill pipe clamp (2) at the tank.
  5. Loosen the vent pipe clamp (1) at the tank.
  6. Remove the fuel fill pipe and vent pipe from the tank.
  7. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
    8. Fig 3: Fuel Sending Unit And Fuel Pressure Sensor Electrical Connectors - Cab/Chassis
    GM1238183Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  9. Remove the canister vent solenoid (CVS) line from the fuel tank clips.
    10. Fig 4: Fuel Feed And EVAP Quick Connect Fittings At The Sending Unit - Cab/Chassis
    GM1228206Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the fuel feed and EVAP quick connect fittings from the sending unit. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    12. Fig 5: Fuel Tank Shield - Cab/Chassis
    GM877744Courtesy of GENERAL MOTORS CORP.
  12. Remove the fuel tank shield bolts.
  13. Remove the fuel tank shield.
  14. Place a suitable adjustable jack under the fuel tank.
    15. Fig 6: Fuel Tank - Cab/Chassis
    GM1228169Courtesy of GENERAL MOTORS CORP.
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.
  17. Lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. Cap the fuel and EVAP pipes in order to prevent possible system contamination.
  20. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement .
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.