Ameer Randolph
Removing the fuel tank from a VT Commodore is a complex process that requires careful attention to safety. It is important to depressurise the fuel system and ensure no naked flames or ignition sources are nearby to avoid the risk of fire or explosion. The vehicle should be raised, preferably on a hoist, and all fuel should be drained from the tank using commercially available equipment. Once the vehicle is secure and the fuel is drained, the next steps involve removing the stone guard retaining screws, disconnecting the electrical connector, and placing a drain tray under the fuel filter area. It is recommended to have an extra pair of hands to assist with the process, especially when it comes to lowering the fuel tank and disconnecting the fuel lines.
| Characteristics | Values |
|---|---|
| Step 1 | Depressurise the fuel system |
| Step 2 | Ensure no naked flames or other ignition sources are in the immediate area |
| Step 3 | Siphon fuel from the tank using commercially available equipment |
| Step 4 | Raise the vehicle, preferably on a hoist; alternatively, jack up the diff and place the car on stands |
| Step 5 | Remove the three stone guard retaining screws, then remove the stone guard from under the right-hand rear guard |
| Step 6 | Remove the fuel sender electrical connector from its mounting foot by pulling it forward to dislodge the assembled connector |
| Step 7 | Depress the locking tab and separate the connector halves |
| Step 8 | Place a drain tray under the fuel filter area |
| Step 9 | Ensure all dirt and foreign material is removed from any fuel connection prior to removal |
| Step 10 | Remove the quick-connect fittings to the vapour canister, return line, and fuel filter |
| Step 11 | While supporting the fuel tank in the centre, remove the strap closest to the filler neck after removing the bolt at the front and unhooking the strap from the rear support |
| Step 12 | Remove the nuts and washers from each end of the strap |
| Step 13 | Lower the fuel tank from the vehicle, left side first, to release the fuel filler neck from the body opening |
| Step 14 | Disconnect the pump harness, fuel lines, and breathers, making note of which ones are which (fuel out, return, and breather) |
| Step 15 | To install, reverse the process but carefully align the fill tube neck before cinching up |
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What You'll Learn
Depressurise the fuel system, siphon fuel, and raise the vehicle
Depressurising the fuel system of a VT Commodore involves taking out the fuel relay and fuse and cranking the car. If there is no battery in the car, you can hook up a jumper pack to the positive and negative to depressurise the fuel system.
To siphon the fuel from the tank, use commercially available equipment, such as a siphon pump. Ensure that you never drain or store fuel in an open container due to the possibility of fire or explosion.
When raising a VT Commodore, it is recommended to use a hoist if you have access to one. Alternatively, you can jack up the differential and place the car on stands.
- Remove the three stone guard retaining screws and then remove the stone guard from under the right-hand rear guard.
- Remove the fuel sender electrical connector by pulling it forward to dislodge it from its mounting foot. Depress the locking tab and separate the connector halves.
- Place a drain tray under the fuel filter area and ensure that all dirt and foreign material is removed from any fuel connections before removal.
- Disconnect the vapour canister breather hose and the fuel filter, if required. Fuel will spill, so be cautious.
- Disconnect the earth strap from the spade connector, under the front right-hand strap mounting bolt of the right-hand tank support strap.
- Remove the fuel tank support straps by first removing the centre strap, then the rear retaining nut and washer, and finally, unhook the strap from the front support.
- With the fuel tank supported in the centre, remove the strap closest to the filler neck. Remove the bolt at the front and unhook the strap from the rear support.
- Lower the fuel tank from the vehicle, left side first, to release the fuel filler neck from the body opening.
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Disconnect earth wire, position jack, and remove brackets
To disconnect the earth wire, you must first locate the earth strap under the front right-hand strap mounting bolt of the right-hand tank support strap. Disconnect the earth strap from the spade connector.
Next, to position the jack, it is recommended that you raise the vehicle using a hoist if you have access to one. If not, you can jack up the diff and place the car on stands.
Finally, to remove the brackets, start by removing the three stone guard retaining screws and then remove the stone guard from under the right-hand rear guard. Then, remove the fuel sender electrical connector from its mounting foot by pulling it forward to dislodge the assembled connector. Once released, depress the locking tab and separate the connector halves. Now, remove the fuel tank support straps. Start by removing the centre strap by removing the rear retaining nut and washer, then unhook the strap from the front support. Finally, remove the strap by removing the nuts and washers from each end of the strap.
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Remove straps, bolts, and washers
To remove the straps, bolts, and washers that secure the fuel tank in a VT Commodore, follow these steps:
Begin by locating the fuel tank straps. Typically, there are two straps securing the fuel tank in place, one at the front and another at the rear. These straps are usually bolted to the vehicle's chassis or frame. Using the appropriate size socket or wrench, loosen and remove the bolts that secure the fuel tank straps. Place these bolts and washers aside in a safe place, as you will need to reuse them during the installation process. With the bolts removed, carefully lift and remove the fuel tank straps. Some straps may have rubber bushings or insulation, so take care not to damage these components during removal. At this point, you should be able to access the fuel tank more openly.
Next, locate the bolts and washers that secure the fuel tank to the vehicle. There are usually multiple bolts and washers distributed around the perimeter of the fuel tank. Using the correct size socket or wrench, loosen and remove these bolts. Similar to the strap bolts, it is important to keep these bolts and washers in a secure location as you will need them during reassembly. Once the bolts are removed, carefully lift and shift the fuel tank to access any remaining bolts or attachments.
During this process, be cautious of any fuel lines, hoses, or electrical connections that may still be attached to the fuel tank. Depending on your vehicle's configuration, you may need to detach these connections before completely removing the fuel tank. Always refer to a workshop manual or seek guidance from a qualified mechanic if you are unsure about any steps or procedures. Ensure you take the necessary safety precautions when working with fuel systems, including wearing protective gear and working in a well-ventilated area.
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Lower the tank and disconnect fuel lines
To lower the tank and disconnect the fuel lines, carefully balance the tank as you remove the last bolt and lower the tank to the ground. It needs to be slid toward the passenger side as you lower it to disengage the fuel filler neck. Support the tank in the centre and remove the strap closest to the filler neck. Now, remove the bolt at the front and unhook the strap from the rear support. Finally, remove the strap after taking off the nuts and washers from each end of the strap.
At this point, the fuel tank can be lowered from the vehicle, left side first, to release the fuel filler neck from the body opening. Now, slowly lower the fuel tank and disconnect all the fuel lines from the sender unit. Disconnect the pump harness, fuel lines, and breathers, making note of which ones are which (fuel out, return, and breather).
To install, simply reverse the process but carefully align the fill tube neck before cinching up. It is a good idea to flush the tank before reinstalling.
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Remove the pump and check fittings
To remove the pump and check fittings, begin by removing the fuel pump. This process is made easier if your car is raised, preferably on a hoist. If you do not have access to a hoist, you can jack up the diff and place the car on stands.
Before removing the fuel pump, it is important to depressurise the fuel system and ensure that no naked flames or other ignition sources are in the immediate area. You should also siphon the fuel from the tank, using commercially available equipment. Never drain or store fuel in an open container due to the risk of fire or explosion.
Once the car is raised and the fuel is siphoned, you can begin to remove the fuel pump. Disconnect the pump harness, fuel lines, and breathers, taking note of which lines are which. Remove the bolt at the front of the strap closest to the filler neck, and unhook the strap from the rear support. Finally, remove the strap by taking out the nuts and washers from each end.
With the fuel pump removed, you can now check the fittings. Inspect the area for any dirt or foreign material and ensure that all connections are secure. Pay close attention to the two lines that go to the canister, as one of them may have a different connector that can be tricky to remove.
If you are reinstalling the fuel pump, simply reverse the removal process. Remember to have an extra pair of hands to assist you, as it can be helpful.
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