2002 TrailBlazer gas tank leak
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John Bernard

Wake Forest, NC

#1 Aug 3, 2006
I recently smelled gas fumes in and around the vehicle. After having this investigated at the dealer, they discovered that there was corrosion on top of the tank around a module that feeds the gas to the engine. I don't remember what this module is called. I will have the name once the repairs are completed and I get the large bill. Has anyone else experienced this before? I have yet to approach GM to complain and see if they will foot some of the bill.
I would appreciate comments from others who may have experienced the same problem.
colleen

Woolrich, PA

#2 Aug 10, 2006
I also just started about 1 week ago smelling strong gas fumes in and around the vehicle. I have a 2002 trailblazer. Just had it to one mechanic and he couldnt find where the leak is coming from. He did call dealer to find there was a recall on somthing with the gas line but mine was ok. I will be taking it to another reputable mechanic on monday. Hopefully it wont cost too much or i dont blow up before monday. Keep me posted .
John Bernard

Wake Forest, NC

#3 Aug 10, 2006
Colleen, good luck with your gas leak issue. My TB has been at the dealer since Aug 2. They can't locate the required part anywhere in Canada or the USA. Estimated cost to repair if and when they find the part is $1400 CDN. I am after GM Canada to get some compensation. They are supposed to get back to me tomorrow.
colleen

Woolrich, PA

#4 Aug 11, 2006
I found where the leak is after filling my tank full of gas, of course. I put cardboard under and found a small puddle of gas. Took it over to the garage and he said after the tank is empty he will drop the tank to see exactly whats going on. He did mention corrosion on top of tank. Sounds very similar to your problem. I have a feeling we are not the only 2 with this same problem. I hope GM helps you out. Ill know more on Tues. or so.
John

Wake Forest, NC

#5 Aug 14, 2006
Your problem sounds different from Mine. Mine was leaking when the tank was almost empty. Sounds like yours only happens after you fill the tank. I found out through a friend who is in the car repair business that GM had a recall in March this year that may be your problem. If yours is the EXT model, this may be your solution. The letter to customer states:
"Special policy adjustment - Fuel tank inlet check valve fracture #05012 (March 14, 2005)

Some customers of 2002 model year Chevrolet TrailBlazer EXT and GMC Envoy XL
vehicles may comment on an SES illumination, may be accompanied by a fuel odor,
and/or a few drops of fuel on the ground when refueling the vehicle. This may be
caused by a fracture of a weld on the fuel tank inlet check valve (ICV). The ICV is
located above the full fuel level. A fracture in this area may allow fuel vapors to pass
through and allow droplets of fuel to accumulate on the side of the fuel tank as it passes
over the fracture during refueling.
Special Policy Adjustment
This special policy covers the condition described above for a period of 7 years or
70,000 miles (110,000 km), whichever occurs first, from the date the vehicle was
originally placed in service, regardless of ownership. The repairs will be made at no
charge to the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders
on or afier March 14, 2005, are covered by this special policy and must be submitted
using the labor operation codes provided with this bulletin. Claims with repair orders
prior to March 14, 2005 must be submitted to the Service Contract provider."
John

Wake Forest, NC

#6 Aug 16, 2006
Finally got my TB back. GM was not able to locate the part, but I did the research and found it. GM paid for the parts and I paid the labour.
colleen

Woolrich, PA

#7 Aug 17, 2006
Thanks for the info, I'll pass it along to my mehanic. Glad it worked out for you .
Kirsten

Atlanta, GA

#8 Sep 6, 2006
John wrote:
Your problem sounds different from Mine. Mine was leaking when the tank was almost empty. Sounds like yours only happens after you fill the tank. I found out through a friend who is in the car repair business that GM had a recall in March this year that may be your problem. If yours is the EXT model, this may be your solution. The letter to customer states:
"Special policy adjustment - Fuel tank inlet check valve fracture #05012 (March 14, 2005)
Some customers of 2002 model year Chevrolet TrailBlazer EXT and GMC Envoy XL
vehicles may comment on an SES illumination, may be accompanied by a fuel odor,
and/or a few drops of fuel on the ground when refueling the vehicle. This may be
caused by a fracture of a weld on the fuel tank inlet check valve (ICV). The ICV is
located above the full fuel level. A fracture in this area may allow fuel vapors to pass
through and allow droplets of fuel to accumulate on the side of the fuel tank as it passes
over the fracture during refueling.
Special Policy Adjustment
This special policy covers the condition described above for a period of 7 years or
70,000 miles (110,000 km), whichever occurs first, from the date the vehicle was
originally placed in service, regardless of ownership. The repairs will be made at no
charge to the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders
on or afier March 14, 2005, are covered by this special policy and must be submitted
using the labor operation codes provided with this bulletin. Claims with repair orders
prior to March 14, 2005 must be submitted to the Service Contract provider."
John - I have a 2003 TB Ext and just had to replace the fuel tank.($880)It sounds like my issue is the same as the letter you mentioned above.
Woocubs

Chicago, IL

#9 Sep 22, 2006
Great info John!!!!.. My dealer was not initially aware of this and wanted to charge $900 for a new tank. When I gave them the Special policy adjustment #05012 to refer to, they called back within an hour and agreed it was covered.
Lisa

Orange Park, FL

#10 Oct 12, 2006
I have a 2003 trailblazer ext that had to have the entire gas tank replaced due to the fuel filter fitting detaching from the tank. I kept getting the code 440 and my mechanic could not figure out what to do. So I took it to Chevy and they stated the tank was leaking (which I knew because when I filled it up that day all the gas ran out of it). The cost was $1000.00 and I was told that they have not had any problems with this (which is not true according to many articles on the web). I have reported it to the governmnet and I plan on writing to GM. Any suggersting on how to get back my $1000.00? This is a SAFETY issue!!! I have a feeling that all the 2003 ext are going to have this problem. I only have 53,000 miles on my car!
Kim

Fresno, CA

#11 Oct 12, 2006
I have a 2003 Trailblazer and I smell gas in the car only at certain times. It seems to happen most when it is hot outside and sometimes it is so bad I smell it through the vents and on my clothes/hair. You can also sometimes smell it outside the car. I am currently going through GM to help me out...the dealership will do nothing because they cannot recreate the smell. I have 2 small children and I am very worried that this is a hazard. Any thoughts? Thank you
Karen

AOL

#12 Oct 16, 2006
Just this past week I had my gas tank on my 2004 TB LS. The check engine light came on , took it local Chevy dealer, came back leak at top of tank. He stated it would cost $1450.00 to replace, said there were no recalls, but he had seen it before. So, since he was the dealership he could replace at no charge. Do you know is the might be under the same "Special Adjustment Policy"?
John

New York, NY

#13 Oct 23, 2006
Glad I could be of help to some of you. Have not had any problems since mine was fixed.
Greg

Clatskanie, OR

#14 Oct 23, 2006
I have a 2003 trailblazer LT with 90,000 miles and last week developed a bad gas leak at the front of the gas tank ( 5 gallons plus or minus in 10 minutes)right after I filled it up from empty.The following morning I could not repeat the leak which only happened while the engine was running.I did replace the fuel filter and so far no more leakage. I'm watching it carefully.
Corey

Chandler, AZ

#15 Oct 31, 2006
There seems to be a design flaw with the 2002 thru 2004 Chevy Trailblazer. I have already had my gas tank replaced when the TB was still under factory waranty and now that the waranty is over the same incedent has occurred again. The DTC code is P0440, which indicates that a small crack or fracture has developed in the fuel tank filler neck. This will cause the check engine light to come on and may cause the TB to idle poorly when cold. Even though there should be no sign of visible fluid, in my situation fuid was visible. I am glad to find that I am not the only one with this problem, but I am sorry that the rest of you have to deal with this as well.
Roger

United States

#16 Nov 3, 2006
I have a 2003 TB Ext with only 28,000 miles and it is 39 months old. The "check engine soon" light came on. The dealership said the computer code was PO442. Further investigation found that the nipple on the gas tank where the fill pipe hose connects had a vapor leak (EVAP). The dealer said the only fix is to replace the gas tank, total cost approx $1,000. They said there was no recall. I called GM customer service and they said they might be able to offer "some assistance". I'm curious if others with a 2003 TB have had the same problem.
Tim

Goose Creek, SC

#17 Nov 5, 2006
I'm going through the same problem as Roger but with a 2003 Envoy. Same computer code, but fixed it with a new cgas cap. However, the tank has a small leak where the fill pipe hose connects to the tank. My dealer said about $1150 to repair with a new tank. GM said to get it oficially diagnosed and they may offer some $$$ support.
Lisa

Jacksonville, FL

#18 Nov 11, 2006
I had my fuel tank replaced on my 2003 Trailblazer ext at a cost of $1000.00, anyone know how to get some money back from GM on it? I have e-mail GM twice, but no reply. What number do I need to use to call and complain about it? How do I need to see about the "Special adjustment policy"?
david

San Antonio, TX

#19 Nov 12, 2006
Guys and Gails I have the same problem many of you doin 2003 envoy, go to this web site and lodge a complaint with the NHTSA if it is a clear and present danger from a defect than they should fix it. NHTSA can not act untill they receive a quanty of complaints about said problem. I have already done this and urge you to do the same even if you shell out money for repairs, if this goes to a recall they should reinburse you for your expenes. http://www-odi.nhtsa.dot.gov/ivoq/Consumer.cf...
Bob-Evansville Indiana

Evansville, IN

#20 Nov 13, 2006
They just confirmed that I have a leak in my gas tank of my 2002 Trailblazer. They confirmed it at 69,955 miles. They want $1000 to repair and there is no help from the dealer.

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