How to Remove a Corvette Gas Tank

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Chevrolet has produced the Corvette since 1953. It is normally a front-engine car powered by a V-8 with fuel injection or carburetors. The engine uses the gas tank to receive fuel and to return excess fuel back to the tank in a closed-loop system. The tank in most Corvettes is metal and can be damaged, leaky or rusty, often requiring removal. The tank is commonly at the rear of the car, just in front of the rear fascia holding the taillights. Removal varies by Corvette make and model, so consult an automotive guide for specific procedures for your particular vehicle.

Things You'll Need

  • Fluid transfer pump
  • Metric wrenches
  • Floor jack
  • Jack stands
  • Torx driver
  • Metric line wrenches
  • Pliers
  • Open the fuel filler cap, and insert the hose from the fluid transfer pump. Operate the pump to transfer the gasoline into approved containers for storage of fuel.

  • Open the hood and remove the negative terminal from the battery with a 7 mm wrench.

  • Raise the Corvette with the floor jack, and secure the vehicle with jack stands.

  • Remove the filler assembly by first removing the filler door with the Torx driver. Peel up the rubber around the fuel filler neck.

  • Remove the feed, vapor and return hoses with a pair of line wrenches. Disconnect the electrical connectors; you can usually do this with no tools.

  • Remove the two Torx bolts holding the license plate. Pull the plate loose and store it safely.

  • Remove the two 13 mm bolts holding the fascia to the impact bar.

  • Remove the spare tire and carrier, using multiple wrenches and sockets.

  • Remove the rear exhaust section. Do this by pulling out the bolt from the rear mount near the back flange, usually a 15 mm; then remove the bolt over each muffler.

  • Detach and remove the inner fender braces. Disconnect the antenna ground wire with a 10 mm socket.

  • Disconnect the remaining support cables from the fuel tank.

  • Remove all lights from the rear fascia, including the four tail, backup and license plate lights. Pull out all the retainers for the rear fascia except the four bolts holding the fascia to the frame extension.

  • Tilt the fascia away from the rear of the car while sliding the gas tank out of the vehicle. This is best accomplished with another person helping. Clean any fluids that were spilled.

Tips & Warnings

  • Plan on two to four hours to accomplish this task, depending on your experience.
  • Contents of a fuel tank are explosive; follow proper safety standards.
  • If gasoline makes contact with your skin, clean the affected areas immediately.

References

  • "Chevrolet Corvette Automotive Repair Manual;" Mike Stubblefield; 1991
  • "1991 Corvette Service Manual;" General Motors Corp.; 1990
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