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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 - REAR)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. With the aid of an assistant, place the fuel tank on the jack.
  3. Raise the fuel tank.
    Fig 1: Fuel Tank Assembly (Cab/Chassis - Rear)
    GM1228170Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel tank strap bolts.

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

  6. Remove the jack from under the fuel tank.
    7. Fig 2: Fuel Tank Shield (Cab/Chassis - Rear)
    GM1228172Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel tank shield.
  8. Install the fuel tank shield bolts.

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

  9. Lower the vehicle.
    10. Fig 3: Fuel Feed And EVAP Quick Connect Fittings At Fuel Tank
    GM1228189Courtesy of GENERAL MOTORS CORP.
  10. Remove the caps from the fuel/EVAP lines.
  11. Connect the fuel feed and EVAP quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  12. Disconnect the fuel tank pressure sensor electrical connector.
    13. Fig 4: Fuel Fill Pipe Assembly (Cab/Chassis - Rear)
    GM1228175Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel fill and vent hoses to the tank.
  14. Tighten the fuel vent pipe hose clamp (1) at the tank.
  15. Tighten the fuel fill pipe hose clamp (2) at the tank.

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

  16. Refill the fuel tank.
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  19. 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.