GM Metro/Sprint 1985-1993 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1 and 2

Carbureted Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel gauge lead wire after removing the rear seat cushion.
  4.  
  5. To release the pressure in the fuel tank, remove the fuel filler cap and then, reinstall it.
  6.  
  7. Due to absence of fuel tank drain plug, drain the fuel tank by pumping or siphoning the fuel out through the fuel feed line.
  8.  
  9. Raise and support the vehicle safely.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel tank and lines - carbureted engine

  1. Remove the three hoses from pipes.
  2.  
  3. Remove fuel filler hose and breather hose.
  4.  
  5. Remove the fuel tank from the vehicle.
  6.  

To install:
  1. Install the fuel tank.
  2.  
  3. Install the fuel filler hose and breather hose.
  4.  
  5. Install the three hoses on the pipes.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the fuel gauge lead wire and install the rear seat cushion.
  10.  
  11. Fill the fuel tank.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Turn the ignition key ON and allow the fuel system to prime.
  16.  
  17. Start the engine and check for leaks.
  18.  



Click image to see an enlarged view

Fig. Fig. 2: Fuel tank and lines - fuel injected engine

Fuel Injected Engine
  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the fuel filler cap from the fuel tank.
  4.  
  5. Have a Class B fire extinguisher near the work area. Use a hand operated pump device to drain as much fuel through the fuel filler neck as possible.
  6.  
  7. Use a siphon to remove the remainder of the fuel in the tank by connecting the siphon to the fuel pump outlet fitting.
  8.  


CAUTION
Never drain or store fuel in an open container because there is the possibility of a fire or an explosion.

  1. Reinstall the fuel filler cap.
  2.  
  3. Remove the rear seat cushion from vehicle (if so equipped).
  4.  
  5. Disconnect the fuel pump motor connector and sending unit electrical connectors.
  6.  
  7. Disconnect the wire harness grommet and harness through the vehicle floor pan.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the fuel filler hose clamp from the filler neck assembly.
  12.  
  13. Remove the fuel breather hose clamp from the filler neck assembly.
  14.  
  15. Remove the fuel filter inlet hose clamp and hose from the filter.
  16.  

A small amount of fuel may be released after the fuel hose is disconnected. In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop towel.

  1. Remove the fuel vapor clamp and hose, and fuel return hose clamps and hose from the respective fuel lines.
  2.  
  3. Using a suitable transaxle jack, support the fuel tank.
  4.  
  5. Remove the fuel tank retaining bolts and lower the tank.
  6.  

To install:
  1. Reconnect all fuel hoses, lines and the fuel breather hose to the fuel tank.
  2.  
  3. Place the fuel tank in its proper space using the transaxle jack, Install the fuel tank retaining bolts.
  4.  
  5. Remove the transaxle jack.
  6.  
  7. Reconnect all fuel hoses, lines and the fuel breather hose to the fuel tank.
  8.  
  9. Install the fuel breather hose and hose clamp to the filler neck assembly.
  10.  
  11. Install the fuel vapor hose and hose clamps. Install the fuel return hose and hose clamp to the respective fuel lines.
  12.  
  13. Install the fuel filter inlet hose and hose clamp to the filter.
  14.  
  15. Lower the vehicle. Install the wire harness and grommet through the vehicle floor pan.
  16.  
  17. Connect the fuel pump motor and the sending unit connectors.
  18.  
  19. Install the rear seat cushion. Reconnect the negative battery cable.
  20.  

 
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