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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 973 (ENGINE CONTROLS - 6.6L (LB7) (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 the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel pipes.
  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 1: Fuel Tank, Strap & Bolts (Cab/Chassis - Rear)
    GM877748Courtesy 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. Fig 2: Fuel Tank Shield & Bolts (Cab/Chassis - Rear)
    GM877746Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Connect the fuel feed/return pipes to the sending unit. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 3: Fuel Feed/Return Pipes At Sending Unit (Cab/Chassis - Rear)
    GM881567Courtesy of GENERAL MOTORS CORP.
  12. Connect the sending unit electrical connector (2).
    13. Fig 4: Sending Unit Electrical Connector & Fuel Pump Electrical Connector
    GM877754Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel fill and vent hose to the tank.
    14. Fig 5: Fuel Fill And Vent Hose (Cab/Chassis - Rear)
    GM877741Courtesy of GENERAL MOTORS CORP.
  14. Tighten the fuel fill and vent hose clamps at the tank.

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

  15. Fill the fuel tank.
  16. Install the fuel fill cap.
  17. Install 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.
  18. Command the fuel transfer pump on with a scan tool.
  19. Test for fuel leaks.
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.