Fuel Tank Replacement. Chevrolet Beretta 1996

For 1990-2009 cars

### Removal Procedure

1. Remove the negative battery cable.

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 fuel tank. Refer to Fuel Tank Draining
3. Raise vehicle and suitably support.
4. Remove the fuel sender electrical connector.
5. Remove the muffler hanger bolts.
6. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.

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

7. Remove the hoses from fuel tank sender. Grasp filter and one nylon fuel connection line fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for other nylon fuel connection line fitting.
8. Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
9. Remove the quick connect fittings by pulling release tabs back on fuel line quick connector and pulling apart.
10. Remove the hoses at tank from filler, vent and vapor pipes.
11. With aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps.
12. Remove the tank from vehicle.
13. Remove the sound insulators.

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

14. Remove the fuel sender assembly from tank. Refer to Fuel Sender Assembly Replacement

### Installation Procedure

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

Tighten
Tighten the bolts to 35N·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.

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.

5. Install the hoses to filler, vent and vapor pipes.
6. Install the nylon fuel feed and return connecting line quick-connect fittings to fuel sender.

- | Apply a few drops of clean engine oil to the male connector tube ends.

- | Push connectors together to cause the retaining tabs/fingers to snap into place.

- | Once installed, pull on both ends of each connection to make sure they are secure.

7. Install the exhaust rubber hangers.
8. Install the muffler hanger bolts.

Tighten
Tighten the bolt to 15 N·m (11 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.

10. Install the fuel tank sender electrical connector.
11. Lower vehicle.
12. Refill tank.
13. Install the negative battery cable.
14. Inspect for fuel leaks.

13.1. | Turn the ignition to ON position for 2 seconds.

13.2. | Turn to OFF for 10 seconds.

13.3. | Again turn the ignition to the ON position.

13.4. | Check for fuel leaks.