Fuel Tank Removal in a 2002 Chevy Blazer

The 2002 Chevrolet Blazer was equipped with a 4.3-liter V-6 engine capable of producing 190 horsepower. The 2002 Chevrolet Blazer was available in two-wheel-drive and four-wheel-drive versions. The 2002 Blazer was also available in two-door and four-door models. The 2002 Blazer fuel tank is located beneath the truck on the driver's side, and is mounted parallel to the front-to-rear chassis rails.

Instructions

Removing the Fuel Tank with Pump

1

Drain the tank, using a siphon pump and gas cans. Raise the hood of the Blazer. Disconnect the negative battery cable from the battery, using an 8 mm wrench. Open the fuel pressure testing port on the driver's side fuel rail. Wrap a rag or towel around the tip of a screwdriver. Insert the screwdriver against the fuel pressure tester port Schrader valve and depress the valve. Relieve the fuel pressure while allowing the rag to soak up any fuel spray. Remove the fuel filler cap from the filler tube.

2

Raise the rear of the truck with a jack. Place jack stands beneath the rear axle housing. Lower the truck onto the stands. Lay on the driver's side of the Blazer, in front of the rear wheel. Slide your body in position to access the fuel filler tube and the vapor tube hose clamps. Loosen both clamps with a ratchet and socket. Separate the fuel filler tube and vapor tube from the rubber hoses extending from the fuel tank.

3

Position yourself at the rear of the Blazer, and slide beneath the truck to access the fuel tank.The fuel tank is mounted along the driver's side of the Blazer, parallel to the front-to-rear chassis rails. Place a plank of wood on top of your jack, and raise the jack to the bottom of the fuel tank. Do not push up on the bottom of the tank, but allow the wood and jack to act as a shelf. Remove the brush shield from around the tank with a ratchet and socket, if equipped.

4

Remove the fuel tank strap mounting bolts with a ratchet, socket, and extension. Move the fuel straps downward and off to the front and rear sides of the tank. Lower the fuel tank halfway between the ground and the bottom of the truck. Remove the small fuel hoses from the fuel pump by hand, which is mounted in the top center of the fuel tank. Unplug the fuel tank electrical connector by hand.

5

Lower the fuel tank onto a large piece of cardboard. Slide the fuel tank out from beneath the rear of the truck, making sure the tank stays on the piece of cardboard. The cardboard will eliminate the possibility of gouging the tank, and also act to prevent static electric discharge between the tank and the ground.

Removing the Fuel Pump from the Tank

6

Insert the tip of a flat head screwdriver against the upward protruding metal tabs on the fuel pump lock ring. Tap the screwdriver with a hammer to turn the ring counterclockwise until the ring pops up and unlocks.

7

Pull the fuel pump out of the old fuel tank, making a mental note of the position of the pump. Rub grease onto the pump's O-ring gasket. Be careful not to run your finger onto the pump lip, as the metal is extremely sharp. Set the pump directly into your new fuel tank, and make sure the pump is facing the same way it was.

8

Push the fuel pump downward with one hand and set the fuel pump lock ring in position. Press the flat-head screwdriver against one of the lock ring vertical tabs, and tap the ring clockwise to lock the ring and fuel pump onto the tank.

Installing the Fuel Tank

9

Lift the fuel tank halfway between the ground and the bottom of the truck, using your jack and wood plank. Place the fuel tank straps back underneath the tank to help stabilize the tank on the jack. Install the small fuel tubes to the top of the fuel pump, then plug the electrical connector back into the fuel pump. Raise the tank up until it presses against the bottom of the truck. Do not push upward on the bottom of the tank once it hits the bottom of the Blazer.

10

Install the fuel tank straps, and tighten the mounting bolts to 33 foot-pounds with a 1/2-inch drive torque wrench and socket. You may have to install an extension onto the torque wrench for maneuvering around the tank. Install the brush shield around the fuel tank and tighten the bolts snug with a ratchet and socket. Lower and remove the jack and wood plank from beneath the truck.

11

Position yourself at the side of the truck again, where you can access the fuel filler and vapor tubes. Insert the tubes into the rubber hoses protruding from the fuel tank. Tighten the hose clamps snug with a ratchet and socket, then 1/4-turn farther to ensure they are truly secure.

12

Install the fuel cap back onto the fuel filler hole, and shut the fuel door. Raise the Blazer off of the jack stands and remove the stands from beneath the truck. Lower the truck to the ground gently.

13

Connect the battery cable and lead back onto the battery. Tighten the lead snug with an 8 mm wrench. Turn the ignition key on the Blazer to the "II" or accessories position then back off. Repeat this key turning three time to prime the new fuel pump, the fuel lines, and the fuel rail with pressurized fuel. Start the truck to ensure proper activation of the fuel system.