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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 974 (ENGINE CONTROLS - 6.6L (LLY) (INTRODUCTION))REPAIR INSTRUCTIONSFUEL FILLER HOSE REPLACEMENT (PICKUP)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.
    Fig 1: Fuel Fill Pipe Assembly (Pickup)
    GM1378752Courtesy of GENERAL MOTORS CORP.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fill hose to the vehicle and tank.
  3. Install the vent hose to the tank.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the fuel tank vent hose and fill hose clamps (1, 2).

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

    5. Fig 2: View Of Rear Axle Vent Hose On The Fuel Fill Pipe (Pickup)
    GM816707Courtesy of GENERAL MOTORS CORP.
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
    6. Fig 3: Fuel Tank Ground Strap Bolt
    GM1238144Courtesy of GENERAL MOTORS CORP.
  6. Position the chassis harness ground strap (2) and fuel tank ground strap (3).
  7. Install the ground strap anti-rotation tab into the frame hole.
  8. Install the fuel tank ground strap bolt (1).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  9. Lower the vehicle.
    10. Fig 4: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel tank filler housing.
  11. Install the fuel tank filler housing to fuel tank fill pipe screws.

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

    12. Fig 5: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  12. Install the fuel tank filler housing to body screws (1) and retainer (2).

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

RENDER: 1.0x

NO RELATED

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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.