Fuel tank removal

[justdennis]

My fuel gauge would fail every time I filled the tank but after driving for 10 miles or so it would start working again. The fault code identified the problem as being the passenger side tank fuel level sensor and my tech2 confirmed it. After checking the forum and watching many youtube video's I decided to do the replacement my self. I found out it is possible to remove your fuel tank without dropping the suspension but I don't recommend it. If you've watched the video of the guy removing the tank on his c6 corvette in the parking lot of his apartment, don't believe for one minute it's as easy as he makes it look. And as hard as it is getting it out it's infinitely harder to get back in. The problem is getting the cross-over tube out far enough to get the tank to drop down and then aligned correctly to reinstall. I had the benefit of having my car on a lift so that helped. The only way I could pull the tube back was to secure a ratchet strap with hose clamp around the right side of the tube then drape the strap over the trans and down to a bar under the car. Ratch it back about 2 or 3 inches then the tank would drop down. The easy part was replacing the sensor, that took about 30 minutes. Unfortunately now the tube was at a bad angle so it would not go back into the tank. I'll cut to the chase, I had the tank in and out five times and destroyed one set of o-rings trying to get the tube back in place. My local Chevy dealer had the 2 o-ring kit in stock for only $135, and the kid behind the parts counter said it with a straight face. I told him I'm seventy years old are you trying to give me a heart attack. I found the exact same kit online for $32 next day free shipping. Next I removed the little storage compartment between the two seats and drilled a hole towards the trunk directly in front of the crossover tube, from there I was able to pull the tube forward and then slowly ease off on the tension from the strap. I also left the tank a little loose to help with alignment. A few more hours of bloodied knuckles and bruised forearms and it was back together. The job would have been a lot easier if GM would have put a removable inspection panel in the tunnel over the tube with access in the trunk. I have no doubt there are others who have done this task faster and easier then I but be fore warned, it's a bitch. Anyway... If you're considering dropping one of your tanks think long and hard about it, then don't.
Thanks to fellow forum member Rubyrod for his suggestions and laughing with me about all the fun we're having with our XLR's.
Carry on

 

[wardlws]

It sounds like you've now got another great story to tell. It reminds me of several of my car repairs when I was in my twenties; once having to ride my bicycle to the part store on a Sunday to get my only car back together before work/school the next day.

I hear you on the YouTube videos... I'm always like, yeah, I could do that in a couple of hours... then, 8 hours later at 10 PM wondering what I was thinking.

 

[justdennis]

So true, some of those youtube video's can be a little misleading.

I have some of those early years car repair nightmares as well. If I had spent as much time and money on the maintenance items as I did on the tape deck and speakers I would have saved myself some headaches.