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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1415 (Engine Control System - 4.2L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (TrailBlazer, Envoy, Bravada, Rainier) >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Oldsmobile Bravada, 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Fuel Tank
    GM730792Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position and support the fuel tank.
  2. Connect the fuel sender electrical connector.
  3. Install the fuel tank straps.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel tank strap attaching bolts.

    Tighten:  Tighten the bolts to 32 N.m (24 lb ft).

    5. Fig 2: Disconnecting/Connecting Fuel Pipes
    GM730737Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel return pipe and the fuel feed pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 3: Disconnecting/Connecting EVAP Vapor & Vent Valve Pipes
    GM730716Courtesy of GENERAL MOTORS CORP.
  7. Connect the EVAP vent valve pipe (2) to the EVAP canister (3).
  8. Connect the EVAP vapor pipe (4) to the EVAP canister (3).
    9. Fig 4: Locating Fuel Tank Electrical Connectors
    GM730919Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel pressure sensor electrical connector (3).
  10. Connect the EVAP vent valve electrical connector (2).
    11. Fig 5: Identifying Fuel Pipe/Hose Components
    GM730806Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel fill hose (2) to the fuel tank.

    Tighten:  Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in).

  12. Lower the vehicle.
  13. Refill the fuel tank.
  14. Install the fuel filler cap.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  16. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  17. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  18. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (TrailBlazer, Envoy) or Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
  19. Install the frame brace. Refer to Frame Brace Replacement (TrailBlazer, Envoy, Bravada) or Frame Brace Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
  20. Lower the vehicle.
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