GM Corsica/Beretta 1988-1996 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



1988-89 Vehicles

See Figure 1

  1. Relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative cable from the battery.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel tank into an approved container. There is no drain plug; remaining fuel in the tank must be siphoned through the fuel feed line (the line to the fuel pump), because of the restrictor in the filler neck.
  8.  
  9. Disconnect the hose and the vapor return hose from the level sending unit fittings.
  10.  
  11. Remove the ground wire screw.
  12.  



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Fig. Fig. 1: Exploded view of the fuel tank assembly - 1988-89 vehicles

  1. Unplug the level sending unit electrical connector.
  2.  
  3. Disconnect the vent hose.
  4.  
  5. Unbolt the support straps, and lower and remove the tank.
  6.  
  7. Installation is the reverse of the removal procedure. Tighten the front retaining strap bolts to 26 ft. lbs. (35 Nm) and the rear strap bolts to 8 ft. lbs. (11 Nm).
  8.  

1990-92 Vehicles

See Figure 2

  1. Relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative cable from the battery.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the tank. There is no drain plug; remaining fuel in the tank must be siphoned through the fuel filler tube.
  8.  
  9. Remove the exhaust pipe rubber hangers.
  10.  
  11. Remove the muffler hanger attaching bolts.
  12.  
  13. Remove the heat shield attaching screws and remove the heat shield.
  14.  
  15. Remove the filler tube and clamp at the fuel tank.
  16.  
  17. Disconnect the fuel tank vent tube and clamp at the fuel tank vent hose.
  18.  
  19. Detach the electrical connector.
  20.  
  21. Disconnect the vapor connecting hose from the fuel level meter.
  22.  
  23. If the nylon feed or return connecting lines become kinked, and cannot be straightened, they must be replaced as follows:
    1. Grasp the fuel level meter fuel feed tube and nylon fuel feed connecting line quick connect fitting and twist the quick connect fitting 1 / 4 turn in each direction to loosen any dirt within the fitting. Repeat for the return nylon fuel connecting line fitting.
    2.  
    3. For the fuel return quick connect fittings, squeeze the plastic tabs of the male end connector and pull the connection apart.
    4.  
    5. For the fuel feed quick connect fitting, select the correct tool from J 37088 tool set or its equivalent, and insert the tool into the female connector, then push inward to release the male connector.
    6.  

  24.  
  25. With the aid of an assistant, support the fuel tank and remove the rear fuel tank retaining strap attaching bolts, fuel tank and both fuel tank retaining straps.
  26.  



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Fig. Fig. 2: Fuel tank assembly mounting - 1989-92 vehicles

To install:
  1. With the aid of an assistant, position and support the fuel tank and install the retaining strap attaching bolts. Tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Connect the nylon fuel feed and return connecting line quick connect fittings to the fuel level meter as follow:
    1. Apply a few drops of clean engine oil to the male tube ends of the engine fuel feed and return pipes.
    2.  
    3. Push the connectors together to cause the retaining the retaining tabs/fingers to snap into place. Pull on both ends of each connection to make sure they are secure. Repeat for the other fitting.
    4.  

  4.  


CAUTION
During normal operation, O-rings, located in the female connector will swell and may prevent proper reconnection if not lubricated. This will prevent a possible fuel leak.

  1. Install the vapor connecting hose.
  2.  
  3. Attach the electrical connector.
  4.  
  5. Install the fuel tank vent hose and clamp.
  6.  
  7. Install the heat shield and retain with the attaching screws.
  8.  
  9. Install the muffler hanger, then secure with the attaching bolts and tighten to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the exhaust pipe rubber hangers.
  12.  
  13. Add fuel and install the fuel filler cap.
  14.  
  15. Connect the negative battery cable.
  16.  

1993-96 Vehicles

See Figures 3 and 4

  1. Relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative cable from the battery.
  4.  
  5. Drain the fuel tank into an approved container.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Detach the fuel sender electrical connector.
  10.  
  11. Remove the muffler hanger bolts.
  12.  
  13. Remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle.
  14.  
  15. Disconnect the quick-connect hoses from the fuel tank sender, as outlined earlier in this section.
  16.  
  17. Detach the hoses at the tank from the filer vent and vapor pipes.
  18.  
  19. With the help of an assistant, support the fuel tank, then disconnect the two fuel tank retaining straps.
  20.  
  21. Remove the tank from the vehicle, then remove the sound insulators.
  22.  
  23. If necessary, remove the fuel sender assembly from the tank, as follows:
    1. Hold the modular fuel sender assembly down, then remove the snapring from the designated slots located on the retainer. Be careful, as the modular fuel sender may spring up from its position.
    2.  
    3. When removing the sender, be careful as the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid float damage. Discard the fuel sender O-ring and replace with a new one.
    4.  
    5. Carefully discard the reservoir fuel into an approved container.
    6.  

  24.  



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Fig. Fig. 3: View of the fuel tank wire routing - 1993-96 vehicles



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Fig. Fig. 4: Fuel tank mounting components - 1993-96 vehicles

To install:
  1. Install the fuel sender assembly, as follows:
    1. Install a new O-ring on the modular fuel sender to the tank.
    2.  
    3. Align the tab on the front of the sender with the slot on the front of the retainer snapring.
    4.  
    5. Slowly apply pressure to the top of the spring loaded sender until the sender aligns flush with the retainer on the tank.
    6.  
    7. Insert the snapring into the designated slots. Be sure the snap ring is fully seated within the tab slots.
    8.  

  2.  
  3. Install the sound insulators.
  4.  
  5. With the help of an assistant, position the fuel tank to the body and secure with the retaining straps. Tighten the strap bolts to 24 ft. lbs. (33 Nm).
  6.  
  7. Connect the hoses to the filler, vent and vapor pipes.
  8.  
  9. Attach the nylon fuel feed and return connecting line quick-connect fittings to the fuel sender.
  10.  
  11. Install the exhaust rubber hangers.
  12.  
  13. Install the muffler hanger bolts and tighten to 11 ft. lbs. (15 Nm).
  14.  
  15. Attach the fuel tank sender electrical connector.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Add fuel and install the fuel filler cap.
  20.  
  21. Connect the negative battery cable.
  22.  

 
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