GM Corvette 1984-1996 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

Ensure an approved dry chemical (Class B) fire extinguisher is near the work area. For safety, additional vehicle supports should be added to the end of the vehicle opposite the work area to keep the vehicle stable on the lift.

  1. Disconnect the negative battery cable and properly relieve fuel system pressure.
  2.  
  3. Drain the fuel tank into an approved container using a hand-operated fuel pump.
  4.  
  5. Remove the 4 screws attaching the fuel door bezel, then remove the bezel and the filler cap.
  6.  
  7. Lift the filler neck housing and disconnect the drain hose from the nipple.
  8.  
  9. Reinstall the filler cap to prevent dirt from entering and remove the filler neck housing.
  10.  
  11. Unplug the fuel sender electrical connector at the tank.
  12.  
  13. Thoroughly clean the surrounding areas to prevent fuel system contamination, then disconnect the fuel hoses from the sender assembly.
  14.  
  15. Remove the license plate and all rear lamps to provide access, then remove the carriage bolts securing the fascia to the impact bar.
  16.  
  17. Raise and support the vehicle safely.
  18.  
  19. Remove the spare tire and tire carrier from the frame.
  20.  
  21. With the aid of an assistant, remove the mufflers as an assembly from the converter.
  22.  
  23. Remove the canister splash shield, if equipped, and both rear inner fender braces at the frame.
  24.  
  25. Remove both rear wheel house liner panels.
  26.  
  27. Remove the antenna ground strap and clip at the antenna base and frame.
  28.  
  29. Disconnect the fuel vapor pipes from the canister or the bottom of the tank, then remove the canister.
  30.  
  31. Remove both fuel tank cables from the stabilizer shaft supports.
  32.  
  33. Remove the 2 bottom fascia-to-energy absorbing pad attaching screws.
  34.  
  35. Remove the marker lamps and spare tire light.
  36.  
  37. Remove the 4 nuts attaching each side of the fascia to the horizontal body retainer. Then remove the 5 nuts securing each side of the outer body retainer to the fascia.
  38.  
  39. Remove 6 side impact bar bolts and loosen the front 2 bolts, 1 on each side. With the aid of an assistant, support the impact bar, and remove the front bar bolts. Remove the impact bar and fuel tank assembly, then separate the fuel tank.
  40.  
  41. If the tank is being replaced, transfer the cables, vapor connections and hoses, fuel sender assembly, and/or fuel connector, as required and applicable.
  42.  



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Fig. Fig. 1: Typical fuel tank replacement



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Fig. Fig. 2: View of the fuel tank insulator used on convertibles



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Fig. Fig. 3: Fuel tank cable routing

To install:
  1. Install the fuel tank to the impact bar assembly and tighten the strap bolts to 11 ft. lbs. (15 Nm) and the strap nuts to 40 inch lbs. (4.5 Nm). Install the impact bar assembly to the vehicle and tighten the 8 bolts to 37 ft. lbs. (50 Nm).
  2.  
  3. Install rear and side fascia to the body retainer using the attaching nuts. Tighten the nuts to 53 inch lbs. (6 Nm).
  4.  
  5. Install the marker lights and the spare tire light sockets.
  6.  
  7. Attach screws to the edge of the fascia and impact bar.
  8.  
  9. Attach the fuel tank cables to the stabilizer shaft supports. Tighten the cable attaching nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the 2 carriage bolts securing the fascia to the impact bar, then install the antenna ground strap and clip.
  12.  
  13. Install both inner fender panels, then the braces to the frame.
  14.  
  15. Connect the vapor hoses to the canister or the bottom of the tank, then install the canister and, if equipped, the canister splash shield.
  16.  
  17. With the aid of an assistant, install the muffler assembly to the rear of the converter.
  18.  
  19. Install the spare tire and carrier to the frame.
  20.  
  21. Lower the vehicle and install all rear lamps.
  22.  
  23. Install the license plate.
  24.  
  25. Connect all lines and electrical connections to the fuel sender assembly.
  26.  
  27. Refill the fuel tank, tighten the fuel filler cap and connect the negative battery cable.
  28.  
  29. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.
  30.  
  31. Install the drain hose, seal and fuel filler door bezel.
  32.  

 
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