How to remove fuel tank

[cowpattyP]

I have an 02 alero 2.2 and need to replace the fuel pump. Any step by step advice?

[BNaylor]

There are none published on the Forum that I know but off the top of my head.

Run out as much fuel as you can. Take it near empty.

Undo gas cap to relieve vapor/fumes.

Remove battery negative cable.

Jack up rear of vehicle to a height where you can get underneath to work. Use jackstands.

Remove the two electrical connectors located on the passenger side next to the gas tank. Undo the wiring harness that runs along the rear of tank and get it out of the way.

Follow the filler neck down to the big hose clamp. Remove so you can get the filler neck tube separated from the line feeding fuel into the tank.

Located any exhaust heat shields and remove because they will be in the way of removing the tank.

The plastic fuel tank is help up by two metal straps. To remove straps at the rear of tank are the strap tie points. Each strap is secured by a 13mm bolt or nut. Remove these one at a time. As you remove the straps the tank will start dropping down. You'll need a second person to help hold and drop the tank.

At the top of fuel tank undo any remaining electrical connectors and any fuel and evaporative emissions lines/hoses.

Once tank is down you will be able to access the fuel pump if that is your goal. Work on tank out from underneath the car. The area where the fuel pump pod assembly will then be noticeable.

Remove the bolts or big c-clip. The pod will come up and out. You may have to snake it out. The float and fuel level sending unit is located at the bottom so be careful when pulling pod out so you do not damage this.

Note: There is a seal make sure it is in good condition. Replace if necessary.

Re-installation is the reverse.

Good luck!

[cowpattyP]

Thanks for the info, it really helped alot! Job complete ....took me a while to get the tank empty though-completely full and my siphon was less than great. Once I got the tank down the job was a breeze! Once again Thanx!

[BNaylor]

Originally Posted by cowpattyP

Thanks for the info, it really helped alot! Job complete ....took me a while to get the tank empty though-completely full and my siphon was less than great. Once I got the tank down the job was a breeze! Once again Thanx!

Not a problem and you are welcome. Good job! and glad you got it resolved.

[procrstinator]

i got as far as takeing the pod out of tank and cant figure how to get the pump out of pod

[9934alero]

Originally Posted by bnaylor3400

The plastic fuel tank is help up by two metal straps. To remove straps at the rear of tank are the strap tie points. Each strap is secured by a 13mm bolt or nut. Remove these one at a time. As you remove the straps the tank will start dropping down. You'll need a second person to help hold and drop the tank.

I noticed that you said the gas tank is plastic. Is this with models later than 1999, because i belive mine is plastic.

[BNaylor]

Originally Posted by 9934alero

I noticed that you said the gas tank is plastic. Is this with models later than 1999, because i belive mine is plastic.

I believe so. I have a '02 GL2 and its plastic.

[9934alero]

I wish mine were plastic, cause then i wouldnt have a leak due do corrosion!