Things You'll Need:
- Siphoning hose
- Fuel container
- Torque wrench
- Floor jack
- Screwdriver
- Towels
- Safety glasses
- Latex gloves
- Fire extinguisher
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Step 1
Disable your car's battery by unplugging the battery ground cable. Pull out the drain hose and the fuel tank filler neck hosing as well. Insert a siphoning hose and empty the fuel into a gas container.
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Step 2
Disconnect all fuel hoses and wiring on and around the fuel tank, including the vapor hose on the fuel-level sender's electrical connector, the fuel feed hose and the rear light cables. Remove the ground antenna strap, the protective fender panels inside your car and the exhaust system to let you take out the tank. Use a torque wrench to take off the tank frame bolts. Untie the tank frame support straps and lower the fuel tank with a floor jack.
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Step 3
Raise the new fuel tank with the floor jack up underneath the car's trunk. Tie the tank-support straps around each end of the tank. Put the tank frame shield on and secure it with the frame bolts. Install the bolts on the left and right sides of the fuel tank. Check the straps and the bolts to make sure they're in place before going further.
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Step 4
Re-attach the rear light cables, including the side marker, taillights and backup lights, to the Corvette's rear. Use a screwdriver to remove the license plate. Set aside the spare tire to put back when installation is complete. Connect the fuel tank cable to the rear stabilizer shift brackets.
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Step 5
Secure the fuel vapor line to the left side of the fuel tank strap with a strap bolt to hold it in place. Connect the antenna ground strap at the fuel tank bottom. Install both fender panels and braces inside your Corvette. Replace the exhaust system at the right rear of the car.
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Step 6
Put the spare tire and its carrier inside your trunk. Install your license plate back onto your car with a screwdriver. Connect the fuel feed hose, fuel return hose and vapor hose onto the fuel-level sender's electrical connector, located on top of your Corvette's fuel tank. Put the drain hose and fuel tank filler neck hosing through the top of the fuel-level sender. Put on the fuel tank filler door.
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Step 7
Turn on your car's battery by plugging in the battery ground cable. Fill your tank with gas and put towels underneath to check for fuel leaks. If there are none, let your engine run briefly. Take your Corvette out for a spin once you confirm everything is working again.
