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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 975 (ENGINE CONTROLS - 4.3L (INTRODUCTION))REPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - CHASSISINSTALLATION 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 and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel feed/return and EVAP pipe assembly.
  2. Connect the fuel feed/return and EVAP pipe clips
  3. Install the fuel feed/return and EVAP pipe clip nuts.
    4. Fig 1: View Of Fuel Feed/Return & EVAP Pipe Assembly
    GM878119Courtesy of GENERAL MOTORS CORP.
  4. Remove the caps from the fuel tank pipes.
  5. Connect the fuel feed/return pipes at the fuel tank pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 2: View Of Fuel Feed/Return Pipes At Fuel Tank
    GM878130Courtesy of GENERAL MOTORS CORP.
  6. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  7. If equipped with 4WD, install the fuel feed/return and EVAP pipes to the clip on the transfer case.
  8. Install the fuel feed/return pipe and EVAP pipe clip to the transmission.
    9. Fig 3: View Of Fuel Feed/Return Pipe & EVAP Pipe Clip
    GM300385Courtesy of GENERAL MOTORS CORP.
  9. Lower the vehicle.
  10. Install the fuel feed/return pipe bracket to the stud.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  11. Install the fuel feed/return pipe bracket nut.

    Tighten:  Tighten the nut to 25 N.m (18 lb ft).

  12. Remove the caps from the fuel feed/return and EVAP pipes.
  13. Connect the EVAP pipe (1).
  14. Connect the fuel feed/return pipes (4) at the engine pipes (5).

    Tighten:  Tighten the fittings to 28 N.m (21 lb ft).

    15. Fig 4: View Of EVAP Pipe, Fuel Feed/Return Pipes & Engine Compartment Pipes
    GM583167Courtesy of GENERAL MOTORS CORP.
  15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement .
  16. Tighten the fuel fill cap.
  17. 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.
  18. Inspect for leaks using the following procedure:
    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.