How to Install a Fuel Tank in a Geo Metro

The Geo Metro is a small compact car, but the Metro handles the same way as bigger Geo models. The Geo Metro is similar to the Chevrolet Sprint as well as the Chevrolet Metro. Check your fuel tank for any cracks or corrosion. If you see any damage, install a new fuel tank in your 1993 to 2008 model Metro. Follow the manufacturer's guidelines before beginning the tank removal and installation process.

Difficulty: Challenging

Instructions

Things You'll Need:

• Siphon hose
• Fuel container
• Floor jack
• Wooden board
• Fuel tank
• Torque wrench
• Towels
• Fan
• Fire extinguisher

1. Disconnect the negative battery cable from the car battery. Reduce fuel pressure by taking off the fuel filler cap from the fuel tank. Use a siphon hose to empty the remaining fuel into a fuel container. Put the filler cap back on and take off the rear seat cushions to gain top access to the trunk.

2. Unplug the fuel pump motor connector and sending unit electrical connectors on top of the fuel tank. Also remove the wire harness from the fuel tank bottom. Take off fuel lines and fuel hoses. Loosen the tank strap bolts and the fuel tank retaining straps. Lower the fuel tank to the ground with a floor jack and a wooden board supporting it.

3. Get a replacement fuel tank from any auto supply stores if your current fuel tank is too corroded or has too many cracks. Raise the fuel tank back underneath the trunk. Reconnect the fuel lines and the fuel breather hose back into the top of the fuel tank. Install the fuel tank retaining bolts with a torque wrench. Wrap the tank retaining straps around each end of the tank.

4. Install the fuel vapor hose and the hose clamps to hold it in place. Also connect the fuel return hose, the fuel filter inlet hose. Put the hose clamps on each hose to connect them better to the fuel tank. Attach the wire harness back around the bottom of the fuel tank.

5. Reconnect the fuel pump motor and the sending unit connectors to the top of the fuel tank. Pour the fuel back into the fuel tank. Put the rear seat cushion back on and activate the car battery by plugging in the negative battery cable. Cover the fuel tank with the fuel tank filler cap.

6. Check the car for any fuel leaks by putting a towel underneath to catch any leaks. Also inspect the car for any loose wires. Start your car and let the engine run briefly and look for any other leaks. If everything is fine, drive your car like you normally do and enjoy your new fuel tank.

Tips & Warnings

• Make sure your work area well ventilated to avoid breathing in fuel or any other car fumes for too long. Get a fan to better circulate the air around your work space and keep you from passing out from the fumes.
• Never leave your fuel container open because the fuel could cause a possible fire if the container spills onto an easily flammable area. Make sure your fuel container is completely shut before storing it anywhere. Also, keep a fire extinguisher close by in case of a fire.

Who Can Help Sponsored