GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Corsica 🢒 Engine 🢒 Engine Controls - 2.2L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Disconnect the negative battery cable.

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle and suitably support.

    4. 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.

  4. Disconnect the fuel sender electrical connector.
  5. Remove the muffler hanger bolts.
  6. Remove the exhaust rubber hangers. Allow the exhaust system to rest on the rear axle.
  7. Disconnect the hoses from fuel tank sender.
  8. Grasp the filter and one nylon fuel connection line fitting. Twist the quick-connect fitting 1/4 turn in each direction in order to loosen any dirt within the fitting. Repeat for the other nylon fuel connection line fitting.

    9. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

  9. Using compressed air, blow out dirt from quick-connect fittings at the end of the fuel filter.
  10. Remove the quick connect fittings by pulling the release tabs back on the fuel line quick connector. Pull apart.
  11. Disconnect the hoses at the tank from the filler, the vent and the vapor pipes.
  12. With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps.
  13. Remove the tank from vehicle.
  14. Remove the sound insulators.
  15. Remove the fuel sender assembly from the tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Important: Inspect all connectors for dirt and burrs. Clean or replace the components/assemblies as required. Inspect the fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

  1. Install the fuel sender assembly to the tank. Refer to Fuel Sender Assembly Replacement .
  2. Install the sound insulators.
  3. With the aid of an assistant, install the fuel tank to the body.
  4. Install the fuel tank retaining straps.

    5. Tighten
    Tighten the bolts to 35 N·m (26 lb ft).

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Connect the hoses to filler, vent and vapor pipes.

    6. Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

  6. Install the nylon fuel feed and return connecting line quick-connect fittings to the fuel sender.
    7. • Apply a few drops of clean engine oil to the male connector tube ends.
    • Push the connectors together in order to cause the retaining tabs/fingers to snap into place.
    • Once installed, pull on both ends of each connection in order to ensure that they are secure.
  7. Install the exhaust rubber hangers.
  8. Install the muffler hanger bolts.

    9. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

  9. Connect the fuel tank sender electrical connector.
  10. Lower the vehicle.
  11. Refill the tank.
  12. Connect the negative battery cable.
  13. Inspect for fuel leaks through the following steps:
    14. 13.1. Turn the ignition to the ON position for two seconds
    13.2. Turn the ignition to the OFF position for ten seconds.
    13.3. Turn the ignition to the ON position
    13.4. Check for fuel leaks.