GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Caprice 🢒 Engine 🢒 Engine Controls - 4.3L (Caprice Only) and 5.7L 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 12664 Size: SH

    Caution: Provide additional support when a vehicle is on a hoist in the following ways:

       • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
       • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
    Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  3. Drain the fuel tank. Refer to Draining Fuel Tank.
  4. Raise the vehicle.
  5. Remove the lower fuel tank shield attaching screws and the lower fuel tank shields from the upper fuel tank shield.

    6. Object Number: 12661 Size: SH
  6. Wipe the vent hose connection at the fuel filler vent pipe.
  7. Disconnect the vent hose (1) and the clamp (2).
  8. Wipe the fuel filler pipe connection at the fuel tank.
  9. Disconnect the fuel filler pipe (4) and the clamp (3).

    10. Object Number: 12666 Size: SH
  10. Wipe the EVAP hose connection at the fuel sender.

    11. Notice: 

       • Replace kniked nylon fuel feed or return pipes that cannot be straightened.
       • Do not repair nylon fuel feed or return pipes. Replace damaged pipes.

  11. Disconnect the EVAP hose (1) and the clamp (2).
  12. Disconnect the fuel feed (3) and the fuel return (4) quick-connect fittings from the fuel sender assembly. Refer to Servicing Quick-Connect Fittings.
  13. Disconnect the fuel sender electrical connector.
  14. With the aid of an assistant, support the fuel tank.

    15. Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  15. Remove the fuel tank strap front attaching bolts and the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. If the fuel filler pipe needs to be replaced, remove the fuel filler pipe attaching screws, the ground strap (Wagon only), and the fuel filler pipe.
  18. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement.
  19. Remove the fuel tank vent hose.

Installation Procedure

    Object Number: 12661 Size: SH
  1. Install the fuel tank vent hose.
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement.
  3. If the fuel filler pipe was replaced, install the fuel filler pipe, the ground strap (Wagon only), and the fuel filler pipe attaching screws.

    4. Tighten

        • Tighten the fuel filler pipe attaching screws to 6 N·m (53 lb in) (Except Wagon) and 1.9 N·m (17 lb in).
        • Tighten the fuel filler pipe ground strap screw (Wagon only) to 4 N·m (35 lb in).
  4. With the aid of an assistant, position and support the fuel tank.
  5. Install the front fuel tank strap attaching bolts.

    6. Tighten
    Tighten the front fuel tank strap attaching bolts to 32 N·m (24 lb. ft.).

  6. Connect the fuel filler pipe (4) and the clamp (3).
  7. Connect the fuel tank vent hose (1) and the clamp (2).
  8. Connect the fuel sender electrical connector.

    9. Object Number: 12666 Size: SH
  9. Connect the fuel feed (3) and the fuel return (4) quick-connect fittings to the fuel sender assembly. Refer to Servicing Quick-Connect Fittings.
  10. Connect the EVAP hose (1) and the clamp (2).

    11. Object Number: 12664 Size: SH
  11. Install the lower fuel tank shields on the upper fuel tank shield with the attaching screws.

    12. Tighten
    Tighten the lower fuel tank shield attaching screws to 1 N·m (9 lb in).

  12. Lower the vehicle.
  13. Refill the fuel tank.
  14. Install the fuel filler cap.
  15. Connect the negative battery cable.
  16. Inspect for leaks.
    17. 16.1. Turn the ignition switch ON for two seconds.
    16.2. Turn the ignition switch OFF for ten seconds.
    16.3. Turn the ignition switch ON.
    16.4. Check for fuel leaks.