Replacing The Fuel Tank In A 2003 Vibe

Replacing the fuel tank in a 2003 Pontiac Vibe can be a challenging task. While it is possible to do it yourself, it is important to exercise extreme caution when working with flammable liquids like gasoline. Before beginning, ensure you have the necessary tools and a clear understanding of the process. The first step is to drain the existing fuel tank and disconnect the fuel pump lines. You will then need to remove the rear seat, driveshaft, and charcoal canister to access the fuel tank. Finally, you can install the new fuel tank and reconnect all the components.

Removing the gas tank

To remove the gas tank from a 2003 Pontiac Vibe, you will need the following tools:

• 14mm socket—used to undo the bolts to the rear seat to get to the fuel pump lines, the gas tank straps, and the four bolts holding the drive shaft to the rear diff.
• Flat screwdrivers—to poke and disconnect the fuel lines (although it is recommended to use quality fuel line disconnect tools).
• 10mm socket—used to undo the bolts holding the e-brake cables to their brackets that wrap around the gas tank.
• 12mm socket—used for the bolts to the charcoal canister on the tank.
• Object to hold up the rear driver shaft (a 5-gallon bucket will do).
• Bungee cords to hold up the rear seat and charcoal canister.
• 17mm socket.
• Something to catch the fuel in when you undo the filler neck and other gas lines.

You will also need the following parts:

• New gas tank straps.
• New gas tank—ensure you order one for the AWD as the FWD is different.

Removal

• Unbolt the four 14mm bolts holding the rear seat bottom and use a bungee cord to hold it up and out of the way. You can now access the fuel pump.
• Undo the fuel pump lines/connectors so you won't fight it when you drop the tank.
• Crawl under the car and undo the four bolts holding the driveshaft to the rear diff. You may need to put the car in neutral to rotate it to access all bolts, and back into park to break them loose.
• Undo the carrier bearing bracket bolts to the rear drive shaft. This must be removed to give you enough room to get the tank out. Support the drive shaft out of the way.
• Unbolt the charcoal canister and bungee cord it to the rear spring out of the way.
• Unbolt the 10mm bolts holding the e-brake cables to their brackets around the tank.
• Loosen the hose clamp connecting to the filler neck and have a catch bucket ready for the fuel that spills out.
• Undo the front bolt on the gas tank straps. You won’t be able to reach the rear ones with the tank in.
• Now you should be able to wiggle the tank around and get it most of the way out.
• To totally remove the tank, you will need to undo some of the charcoal canister vent lines.

Reinstallation

• Tighten the bolts to the rear of the gas tank straps before installing the new tank. You cannot reach these bolts with the tank in place.
• Ensure you are hooking up all of the vent lines correctly.

Disconnecting fuel pump lines

Disconnecting the fuel pump lines is a crucial step when changing the fuel tank of your 2003 Vibe. Here's a detailed and instructive guide on how to do it:

Prepare Your Workspace and Gather Tools:

Before you begin, ensure you have the necessary tools, including safety glasses, rubber gloves, and a set of wrenches. A fuel line disconnect tool, pliers, and a catch pan for spilled fuel are also recommended.

Locate the Fuel Pump and Fuel Lines:

The fuel pump and fuel lines are typically located near the fuel tank or engine compartment. Consult your 2003 Vibe's manual or online resources to identify their exact location.

Relieve System Pressure:

Locate and remove the fuel pump fuse or relay. Then, start the engine and let it run until it stalls to relieve pressure from the fuel lines. This step is crucial for safety and to prevent fuel spray during disconnection.

Disconnect the Fuel Lines:

Using your pliers or a specialized tool, carefully remove any clips or connectors holding the fuel lines in place. Hold the lines gently to avoid unnecessary tension. Once the clips are removed, use your wrench to loosen the fittings on the fuel pump, and then gently pull the lines away. Be prepared for potential fuel spills with a rag or container.

Undo the Fuel Pump Lines/Connectors:

Access the fuel pump by unbolting the four rear seat bolts and using a bungee cord to secure the seat bottom out of the way. Undo the fuel pump lines and connectors to prevent any issues when dropping the tank.

Additional Steps for a Smoother Process:

• Crawl under the car and undo the four bolts holding the driveshaft to the rear differential. You may need to put the car in neutral to access all the bolts.
• Undo the carrier bearing bracket bolts on the rear driveshaft and support the driveshaft out of the way.
• Unbolt the charcoal canister and bungee cord it to the rear spring.
• Unbolt the 10mm bolts holding the e-brake cables to their brackets around the tank.
• Loosen the hose clamp connecting to the filler neck and have a catch bucket ready for any fuel spillage.
• Undo the front bolt on the gas tank straps; you won't be able to reach the rear ones with the tank in place.

By carefully following these steps, you can successfully disconnect the fuel pump lines when changing the fuel tank of your 2003 Vibe. Remember to take your time, work in a well-ventilated area, and always prioritize safety when dealing with fuel.

Disconnecting the drive shaft

Firstly, ensure you have the right tools for the job. You will need a 14mm socket, a wrench, and possibly a flat-head screwdriver. It is also recommended to have a second pair of hands to help with the process.

Now, to the Vibe. Park your car on a level surface and engage the parking brake. It is also a good idea to place blocks behind the rear tires for added safety.

Next, locate the four bolts holding the drive shaft to the rear differential. You may need to put the car in neutral to rotate the shaft and access all the bolts. Once you have located them all, use your 14mm socket to loosen and remove them.

At this point, you should be able to gently pull the drive shaft away from the differential. If it is stuck, try tapping it gently with a soft hammer or mallet. Be careful not to use too much force, as you do not want to damage any components.

Once the drive shaft is free, you can set it aside and continue with the next steps of changing the fuel tank. Remember to mark or note the position of each bolt to make reassembly easier.

It is important to note that disconnecting the drive shaft is a crucial step when preparing to tow certain types of vehicles, especially those with power going to the rear or all wheels. This is because failing to do so can cause serious damage to the drivetrain and transmission.

Removing the charcoal canister

To remove the charcoal canister from a 2003 Vibe, you will need the following tools:

• A 12mm socket
• Bungee cords
• A 10mm socket
• A flat-head screwdriver
• A 14mm socket
• A 17mm socket
• A 5-gallon bucket
• An object to catch fuel in

The first step is to unbolt the four rear seat 14mm bolts holding the seat bottom on. Then, bungee cord the seat out of the way so you can access the fuel pump. Next, undo the fuel pump connectors.

Now, crawl under the car and undo the four bolts holding the driveshaft to the rear differential. You may need to put the car in neutral to rotate it to access all the bolts, and then back into park to break them loose. Undo the carrier bearing bracket bolts to the rear driveshaft and support the driveshaft out of the way.

Unbolt the charcoal canister and bungee cord it to the rear spring to get it out of the way. Now, unbolt the 10mm bolts holding the e-brake cables to their brackets around the tank. Loosen the hose clamp connecting to the filler neck and have a catch bucket ready for the fuel that spills out.

Undo the front bolt on the gas tank straps; you won’t be able to reach the rear ones with the tank in. Now, wiggle the tank around to get it out. To completely remove the tank, you will need to undo some of the charcoal canister vent lines.

To install the new tank, just follow the above steps in reverse. Ensure you tighten the bolts to the rear of the gas tank straps before installing the new tank. You won't be able to reach these bolts with the tank in place. Make sure you are hooking up all of the vent lines correctly.

Disconnecting the fuel filler neck

Firstly, ensure you have the necessary tools and equipment. You will need a 14mm socket for the rear seat bolts, fuel pump lines, and gas tank straps. A flat screwdriver will be useful for disconnecting the fuel lines, but it is recommended to use fuel line disconnect tools if possible. A 10mm socket is needed for the e-brake cable bolts, and a 12mm socket for the charcoal canister bolts. To hold the rear driver shaft in place, use a 5-gallon bucket or a similar object. Bungee cords will also be handy to secure the rear seat and charcoal canister out of the way. Don't forget to have a container ready to catch any fuel that spills when you disconnect the filler neck.

Now, let's begin the process:

• Unbolt the four 14mm bolts securing the rear seat. Use a bungee cord to hold the seat up and out of the way. This will give you access to the fuel pump and lines.
• Disconnect the fuel pump lines and connectors. This will prevent any tension or leakage when you drop the tank.
• Locate the four bolts holding the driveshaft to the rear differential. You may need to put the car in neutral to rotate the driveshaft and access all the bolts. Loosen and remove these bolts.
• Remove the carrier bearing bracket bolts from the rear driveshaft. This step is crucial to creating enough space to remove the gas tank. Make sure to support the driveshaft and set it aside.
• Unbolt the charcoal canister using a 12mm socket. Use a bungee cord to secure it to the rear spring, keeping it out of your way.
• Locate the 10mm bolts holding the e-brake cables to their brackets. Use the appropriate socket to loosen and remove these bolts. If you skip this step, the cables may get in your way during the tank removal.
• Loosen the hose clamp connecting to the filler neck. Have your fuel catch container ready at this point, as fuel will spill out once the connection is broken.
• Undo the front bolt on the gas tank straps. You won't be able to reach the rear bolts with the tank still in place.
• At this point, you should be able to wiggle the tank and move it out. You may need to disconnect some of the charcoal canister vent lines attached to the tank for complete removal.
• With the tank almost out, pay attention to any remaining lines or connections. Be careful not to damage any other components while removing the tank entirely.

Remember to have a helper or two to make the process easier and safer. Always exercise extreme caution when working with automotive fuel systems to prevent injuries and accidents.

Frequently asked questions