GM Chevy Mid-Size Cars 1964-1988 Repair Guide

DRAINING

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  1. Remove the fuel tank filler cap.
  2.  
  3. Connect a siphon pump to the 1 / 4 in. fuel feed hose (the smaller of the two hoses when applicable) above the rear axle, or under the hood near the fuel pump on the passenger's side of the engine, near the front.
  4.  
  5. Operate the siphon pump until all fuel is removed from the fuel tank. Be sure to reinstall the fuel return hose and the fuel cap.
  6.  

REMOVAL & INSTALLATION



See Figures 1 and 2

1964 Sedan, 1964 Station Wagon and El Camino
  1. Disconnect the negative battery cable.
  2.  
  3. Properly pump the fuel from the tank, as there is no drain plug.
  4.  
  5. Raise and support the vehicle safely using jackstands.
  6.  
  7. Disconnect the fuel line and the gauge sending unit wire from the tank.
  8.  
  9. If equipped, disconnect the vent hose from the tank.
  10.  
  11. Remove the retaining bolts from the tank straps, lower the support straps and then carefully lower the tank from the vehicle.
  12.  

Be sure to store the fuel tank in a cool dry area out of direct sunlight. Keep any source of flame away from the tank, even though it has been drained of most fuel, there is likely an large amount of flammable vapors still stored in the tank.

To install:
  1. Carefully raise the tank into position (an assistant is helpful here), then secure using the support straps and retaining bolts.
  2.  
  3. If equipped, connect the vent hose to the tank, then connect the sending unit connector and fuel line.
  4.  
  5. Remove the jackstands and carefully lower the vehicle.
  6.  
  7. Refill the fuel tank and check for leaks.
  8.  
  9. Connect the negative battery cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The fuel tank is secured under the rear of the vehicle by retaining straps

1965-67 Station Wagon and El Camino
  1. Disconnect the negative battery cable.
  2.  
  3. Properly pump the fuel from the tank, as there is no drain plug.
  4.  
  5. Raise and support the vehicle safely using jackstands.
  6.  
  7. Disconnect the fuel line and the gauge sending unit wire from the tank.
  8.  
  9. If equipped, disconnect the vent hose from the tank.
  10.  
  11. Remove the tank support straps.
  12.  
  13. Remove the frame attaching screws from the front support.
  14.  
  15. Slide the tank forward and then carefully lower it from the car.
  16.  

Be sure to store the fuel tank in a cool dry area out of direct sunlight. Keep any source of flame away from the tank, even though it has been drained of most fuel, there is likely an large amount of flammable vapors still stored in the tank.

To install:
  1. Carefully raise the fuel tank and slide it into position.
  2.  
  3. Install the frame attaching screws to the front support.
  4.  
  5. Install and secure the tank support straps.
  6.  
  7. If equipped, connect the vent hose to the tank, then connect the sending unit connector and fuel line.
  8.  
  9. Remove the jackstands and carefully lower the vehicle.
  10.  
  11. Refill the fuel tank and check for leaks.
  12.  
  13. Connect the negative battery cable.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: Fuel meter and wiring-Chevelle station wagon

1968-77 Sedan and El Camino
  1. Disconnect the negative battery cable.
  2.  
  3. Properly pump the fuel from the tank, as there is no drain plug.
  4.  
  5. Disconnect the fuel gauge sending unit wire from the rear wiring harness connector. On sedans, push the grommet out and work the gauge wire through the trunk floor hole.
  6.  
  7. Raise and support the vehicle safely using jackstands.
  8.  
  9. Remove the fuel gauge wire screw from the underbody.
  10.  
  11. Disconnect the fuel line at the sending unit pickup line.
  12.  
  13. Remove the vent hose (hoses for evaporative control on 1970 and later models).
  14.  
  15. Remove the tank filler neck bolt on the El Camino.
  16.  
  17. Remove the strap retaining bolts, lower the support straps, and carefully lower the tank from the car.
  18.  

Be sure to store the fuel tank in a cool dry area out of direct sunlight. Keep any source of flame away from the tank, even though it has been drained of most fuel, there is likely an large amount of flammable vapors still stored in the tank.

To install:
  1. Carefully raise the tank into position (an assistant is helpful here), then position and secure the tank support straps.
  2.  
  3. For the El Camino, install the filler neck bolt.
  4.  
  5. For 1970 and later models so equipped, install the vent hose.
  6.  
  7. Connect the fuel line at the sending unit pickup line.
  8.  
  9. Install the fuel gauge wire screw to the under body.
  10.  
  11. Remove the jackstands and carefully lower the vehicle.
  12.  
  13. Connect the fuel gauge sending unit wire to the rear harness connector. On sedans, be sure to push the gauge through the trunk floor hole and properly seat the grommet.
  14.  
  15. Refill the fuel tank and check for leaks.
  16.  
  17. Connect the negative battery cable.
  18.  

1968-77 Station Wagon
  1. Disconnect the negative battery cable.
  2.  
  3. Properly pump the fuel from the tank, as there is no drain plug.
  4.  
  5. Raise and support the vehicle safely using jackstands. Position the jackstands under the frame, leaving the rear axle free.
  6.  
  7. Lower the rear axle into the full rebound position, and remove the left rear wheel assembly.
  8.  
  9. Disconnect the fuel gauge sending unit wire at the rear wiring harness.
  10.  
  11. Remove the fuel tank front shield.
  12.  
  13. Remove the fuel gauge ground wire from the rear quarter panel.
  14.  
  15. Remove the fuel line and wires from the gauge sending unit.
  16.  
  17. On 1974 and later models, remove the left rear shock absorber and lift the right rear wheel slightly to allow movement of the left wheel down and out of the way.
  18.  
  19. Remove the strap retaining bolts and carefully lower the tank from the vehicle.
  20.  

Be sure to store the fuel tank in a cool dry area out of direct sunlight. Keep any source of flame away from the tank, even though it has been drained of most fuel, there is likely an large amount of flammable vapors still stored in the tank.

To install:
  1. Carefully raise the tank into position (an assistant is helpful here), then position and secure the tank support straps.
  2.  
  3. For 1974 and later models, reposition the axle, as necessary, and reconnect the shock absorber.
  4.  
  5. Install the fuel line and wires to the gauge sending unit.
  6.  
  7. Install the fuel gauge ground wire to the rear quarter panel.
  8.  
  9. Install the fuel tank front shield.
  10.  
  11. Connect the fuel gauge sending unit wire to the rear wiring harness.
  12.  
  13. Install the left wheel assembly.
  14.  
  15. Remove the jackstands and carefully lower the vehicle.
  16.  
  17. Refill the fuel tank and check for leaks.
  18.  
  19. Connect the negative battery cable.
  20.  

1978 and Later
  1. Disconnect the negative battery cable.
  2.  
  3. Properly pump the fuel from the tank, as there is no drain plug.
  4.  
  5. Disconnect the fuel gauge sending unit wire from the rear wiring harness connector. On sedans, push the grommet out and work the gauge wire through the trunk floor hole.
  6.  
  7. Raise and support the car safely using jackstands.
  8.  
  9. Remove the fuel gauge ground wire screw from the underbody.
  10.  
  11. Disconnect the fuel line at the sending unit pickup line.
  12.  
  13. Remove the vent hose.
  14.  
  15. Remove the strap retaining bolts, lower the support straps, and carefully lower the tank out of the car.
  16.  

Be sure to store the fuel tank in a cool dry area out of direct sunlight. Keep any source of flame away from the tank, even though it has been drained of most fuel, there is likely an large amount of flammable vapors still stored in the tank.

To install:
  1. Carefully raise the tank into position (an assistant is helpful here), then position and secure the tank support straps.
  2.  
  3. Install the vent hose.
  4.  
  5. Connect the fuel line(s) to the sending unit or sending unit/pump assembly (fuel injected vehicles).
  6.  
  7. Install the fuel gauge wire screw to the under body.
  8.  
  9. Remove the jackstands and carefully lower the vehicle.
  10.  
  11. Connect the fuel gauge sending unit wire to the rear harness connector. On sedans, be sure to push the gauge through the trunk floor hole and properly seat the grommet.
  12.  
  13. Refill the fuel tank and check for leaks.
  14.  
  15. Connect the negative battery cable.
  16.  

SENDING UNIT REPLACEMENT



See Figure 3

For details on sending unit/fuel pump assembly removal and installation on fuel injected vehicles, refer to the procedure earlier in this section.

The sending unit (or sending unit/fuel pump assembly on fuel injected vehicles) is located in the fuel tank assembly. The tank must be removed from the vehicle in order to access the unit which is mounted through the top of the tank. For most vehicles covered in this guide a lockring is used to hold the unit in position. The lockring may be loosened using a hammer and drift punch to carefully drive it counterclockwise, then the unit may be withdrawn from the vehicle.

Be careful not to damage the unit during removal or installation. Also, always take care to see that the arm and pickup are properly positioned upon installation. Be sure that they do not become hung up on the tank and damaged or bent when the unit is inserted.



Click image to see an enlarged view

Fig. Fig. 3: Installing the fuel gauge unit to a common fuel tank

 
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