Replacing The Fuel Tank On A 2002 Trailblazer: Step-By-Step Guide

Replacing the fuel tank on a 2002 Trailblazer is a moderately complicated job that is best performed at a dealership's service department. The fuel tank is filled with fuel through the fill spout, which connects to the fuel tank filler neck. The fuel tank is mounted to the bottom rear of most vehicles and is part of the evaporative emissions control system and the fuel delivery system. The average cost for a Chevrolet Trailblazer Fuel Tank Replacement is between $1,148 and $1,214, with labor costs estimated between $253 and $319, and parts typically priced around $895.

Disconnect the negative battery terminal

Disconnecting the negative battery terminal is a standard procedure when working on car repairs. This is a safety measure to prevent injury and accidental short circuits.

• Ensure the engine is turned off. Do not attempt to remove the battery while the engine is on, as this can cause damage to sensitive electronics.
• Locate the battery. On most vehicles, the battery is located under the hood, but on some models, it may be in the trunk. Refer to your owner's manual to determine the correct location.
• Identify the battery terminals. The negative terminal is usually marked with a "-" symbol and may have a black cable connected to it. The positive terminal will have a "+" symbol and a red cable.
• Using a wrench, loosen the nut on the negative terminal and remove it from the battery post. Ensure that the cable is moved away from the terminal and cannot make contact.
• Once the negative terminal is disconnected, you can proceed to remove the positive terminal if necessary.

It is important to disconnect the negative terminal first. If you remove the positive terminal first and it touches the chassis or engine, it can create a short circuit. Additionally, always make sure to disconnect the battery before performing any work on your Trailblazer's electrical system to avoid accidental short circuits and potential damage to electronic components.

When reconnecting the battery, be sure to follow the correct procedure by first connecting the positive terminal, then the negative. Ensure that all connections are secure and that the battery is mounted firmly in place to prevent vibrations and displacement.

Remove the cross bar

To remove the cross bar, you will need to use a short Phillips screwdriver to loosen the screw on the fuel filter. You will also need to press in on the schrader valve to release any pressure in the lines. Gas may come out of the schrader valve if there is still pressure in the lines. It is important to have a container ready to catch any gas that comes out of the filter/line connections.

Loosen the screw on the fuel filter

To loosen the screw on the fuel filter of a 2002 Trailblazer, follow these steps:

First, remove the gas fill cap. Then, remove the fuel pump relay in the under-hood fuse box. Next, start the engine and let it run until it stalls. Continue to crank the engine for 5-10 seconds after. Now, disconnect the negative battery cable.

Jack up the front driver's side of your Trailblazer, if necessary. Locate the fuel filter directly in front of the fuel tank. Clean the area around the inlet and outlet fittings, making note of the order of the two (the fuel filter is directional).

Place a pan underneath the filter to catch any gasoline that spills out. Unscrew the cap off the bleeder valve and depress it with a screwdriver or pliers to release any remaining pressure, then screw the cap back on.

Use needle-nose pliers or your fingers to squeeze the quick-connect clips and pull off each of the hose fittings one at a time, noting the location of the inlet and outlet tubes. The filter is directional, so some fuel will come out when disconnected.

Now, you can unscrew the filter clamp and remove the old filter. Tilt the old filter into the pan to spill out any excess fuel.

Finally, screw in the new filter, ensuring that the inlet side is facing towards the tank and the outlet towards the engine. Snap the fittings back on, lower your Trailblazer, replace the relay and negative battery cable, and screw on the gas cap.

Start the engine—it may take a few cranks to get the fuel back up.

Release pressure in the lines

To release pressure in the fuel lines of a 2002 Trailblazer, you will need to remove the negative battery terminal. Place a shop towel under and around the Schrader valve. With the key off, press a small screwdriver onto the Schrader valve on the fuel line in the engine compartment until fuel stops dripping from the line. Be prepared to catch fuel when you remove the filter, as it will drip.

You can also try disconnecting the fuel pump and turning the key on and off without cranking. Alternatively, remove the back seat, unscrew the fuel pump cover, unplug the fuel pump, and start the car. Let it run until it dies, and then try to start it again.

Another method is to remove the CIRCUIT RELAY, which is located in the larger of the two plastic fuse boxes near the battery. After the engine stalls, turn off the ignition switch, install the circuit-opening relay, and remove the gas cap to depressurize the fuel tank.

It is important to note that you should always use a rag to protect yourself from fuel spray when disconnecting the hoses. Additionally, be sure to wear eye protection and practice general safety.

Disconnect the fuel lines

Disconnecting the fuel lines is a crucial step in replacing the fuel tank on a 2002 Trailblazer. Here is a detailed guide on how to safely and effectively complete this task:

Before beginning, lay down thick plastic sheeting to catch any fuel spillage and raise the vehicle using car ramps with wooden supports to prevent damage to the concrete. Ensure you have a container ready to catch any fuel that may come out of the filter/line connections.

First, pop the hood and access the fuse box. With the engine running, pull the relay for the fuel pump; the engine will die within a few seconds. Next, crank the engine a few times to relieve pressure and disconnect the negative battery terminal.

Now, you can open the gas cap and remove the crossbar that will obstruct the fuel tank's removal. Using a short Phillips-head screwdriver, loosen the screw on the fuel filter. Press in on the Schrader valve to release any pressure in the lines; if there is still pressure in the lines, gas may come out.

To disconnect the fuel lines, simply press in the clips (which are blue on the filter) and squeeze the other lines by hand. No special tools are needed for this step. Ensure you do not miss any connections, using a flashlight to check if necessary.

Once you have disconnected all the fuel lines, you can proceed to place a jack and a piece of wood under the tank for support before removing the straps. Loosen the hose from the tank to the gas filler tube using a small ratchet and a 7mm socket.

Finally, loosen the straps using a size 15 socket, extension, and 1/2-inch ratchet. With the straps removed, the jack and wood will now be supporting the tank. You may need to jiggle the rearmost strap to get it out of the way.

At this point, you can carefully lower the tank to inspect and disconnect any electrical connections. This detailed guide should help you successfully disconnect the fuel lines as part of the fuel tank replacement process for a 2002 Trailblazer.

Frequently asked questions