GM Corvette 1963-1982 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Exploded view of the fuel tank mounting-1963-67 20 gallon tank and 1966-67 optional 36 gallon tank shown



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Fig. Fig. 2: View of the fuel tank assembly-1968-77 vehicles



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Fig. Fig. 3: Exploded view of the fuel tank assembly-1978-82 vehicles


CAUTION
Exercise extreme caution while servicing the fuel tank. Service the tank only in a well ventilated area. DO NOT smoke or use any type of drop light in the service area.

It is best to run the tank as low on fuel as possible prior to removing the tank.

1963-74 Models

  1. Disconnect the battery cables at the battery.
  2.  
  3. Remove the gas cap and the filler neck boot from the top of the tank. Disconnect the drain tube.
  4.  
  5. Raise the vehicle and support it safely with jackstands.
  6.  
  7. Remove the spare tire compartment (if applicable), spare tire, and spare tire carrier.
  8.  
  9. Loosen the U-clamps and separate the exhaust systems at the transmission crossmember. Disconnect the muffler support brackets and slide the exhaust system rearward.
  10.  
  11. Remove the fuel tank strap bolts and disconnect the gauge unit wiring.
  12.  
  13. Disconnect the fuel lines and allow the fuel to drain into a clean container.
  14.  
  15. Unbolt and remove the tank support. Lower the tank, rotating it toward the front of the vehicle to remove it.
  16.  
  17. Installation is the reverse of the previous steps.
  18.  

1975-82 Models

  1. Disconnect the battery cables at the battery.
  2.  
  3. Remove the gas cap and siphon the remaining fuel from the tank.
  4.  
  5. Remove the filler neck seal and the drain tube.
  6.  
  7. Disconnect the fuel lines and electrical connectors from the inlet and meter assembly.
  8.  
  9. Raise the vehicle and support it safely with jackstands.
  10.  
  11. Remove the spare tire and carrier.
  12.  
  13. Loosen the U-clamps and separate the exhaust system at the transmission crossmember. Disconnect the muffler support brackets and slide the exhaust system rearward.
  14.  
  15. Remove the fuel tank strap bolts and lower the tank from the vehicle.
  16.  
  17. Installation is the reverse of the previous steps.
  18.  

CLEANING THE FUEL SYSTEM




CAUTION
This procedure will not remove fuel vapor. Do not attempt any repair on tank or filler neck where heat or flame is required.

  1. Disconnect the negative battery cable, if not already done.
  2.  
  3. Remove in-line fuel filter and inspect for dirt, rust, or contamination. If filter is plugged, replace but do not install until fuel lines are cleared.
  4.  
  5. Drain the tank into a suitable safety can.
  6.  
  7. Remove fuel meter/fuel pump, located under the filler door.
  8.  
  9. Using a wet sponge, wipe inside liner clean of all foreign material. Rinse out sponge often when wiping liner. Wipe dry. Do not use harsh chemicals when cleaning.
  10.  
  11. Inspect strainer on fuel tank meter/fuel pump. If dirty or clogged, replace with new strainer.
  12.  
  13. Disconnect inlet fuel line at TBI assembly and apply air pressure in direction of fuel flow from filter to TBI.
  14.  
  15. Apply air pressure in direction of fuel flow from fuel tank to filter.
  16.  
  17. Disconnect return fuel line at TBI assembly and apply air pressure from TBI to fuel tank.
  18.  
  19. Connect all fuel lines and install fuel filter. If lines are damaged, see below.
  20.  
  21. Install fuel tank meter/fuel pump with new gasket.
  22.  
  23. Connect fuel lines, fuel vapor pipe and electrical connector. Make sure all connections are tight.
  24.  
  25. Connect negative battery cable and add fuel. Do not reuse contaminated fuel.
  26.  
  27. Start engine and check for fuel leaks. Dispose of contaminated fuel properly.
  28.  

Fuel feed, return and emission pipes or hoses are secured to the underbody with clamp and screw assemblies. Flexible hoses are located at fuel tank, fuel vapor and return lines. The pipes should be inspected occasionally for leaks, kinks or dents. Replace any excessively corroded lines.

Fuel and vapor hoses are specially manufactured. If replacement becomes necessary, it is important to use only replacement hoses meeting manufacturer specifications. Hoses not meeting minimum specifications could cause early part failure or failure to meet emission standards.

Do not use copper or aluminum tubing to replace steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibrations. Do not use rubber hose within 4 in. of any part of the exhaust system or within 10 in. of the catalytic converter. When making repairs, cut a piece of fuel hose about 4 in. longer than portion of the line removed. If more than a 6 in. length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 10 in.

Follow the same routing as the original pipe, and always use screw type hose clamps. Slide hose clamps over replacement part and push the hose an equal amount onto each portion of fuel pipe. Tighten clamps on each side of repair, but do not overtighten. Pipes must be properly secured to the frame to prevent chafing, which could wear a hole in the line.

See Figures 4 through 9



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Fig. Fig. 4: 1963-65 Fuel Injection Specifications



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Fig. Fig. 5: Holley Model 2100 & 2300



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Fig. Fig. 6: Holley 4150 and 4160 Specifications



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Fig. Fig. 7: Carter WCFB & AFB



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Fig. Fig. 8: Rochester Quadrajet Carburetor Specifications



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Fig. Fig. 9: Carburetor Specification

 
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