Replacing Chevy Captiva Fuel Tank: Step-By-Step Guide

Replacing the fuel tank of a Chevrolet Captiva Sport is a complex task that requires a good understanding of car mechanics and safety procedures. The fuel tank is located at the bottom rear of the vehicle and is part of the evaporative emissions control system and the fuel delivery system. Before attempting to replace the fuel tank, it is important to note that fuel vapors and fuel fires can cause injury or death, so proper precautions must be taken to avoid any accidents. The process involves removing the rear seats, the rear seat latch trim, and the floor panel insulator. It is recommended to refer to the Chevrolet Captiva Service Manual for detailed instructions on replacing the fuel tank. The average cost for this replacement is between $479 and $537, including labor and parts.

Remove rear seats, rear seat latch trim and floor panel insulator

To remove the rear seats of a 2013 Chevrolet Captiva (VIN C), refer to the Rear Seat Removal and Installation instructions in the service manual.

To remove the rear seat latch trim, you will need to:

• Remove the rear seats.
• Remove the rear seat latch trim by unscrewing it from the rear seats. Be sure to keep the screws in a safe place.

The next step is to remove the floor panel insulator. This will involve:

• Locating the floor panel insulator, which is typically found under the rear seats.
• Using a flat-head screwdriver to carefully pry the insulator away from the floor.
• Gently lifting and removing the insulator from the vehicle.

Disconnect electrical and vacuum connectors

Disconnecting the electrical and vacuum connectors is a crucial step when replacing the fuel tank in a Chevy Captiva. Here is a detailed guide on how to do this safely and effectively:

Locate the electrical and vacuum connectors – Before you begin, familiarize yourself with the location of the electrical and vacuum connectors. They are usually found near the fuel tank and are responsible for the electrical and fuel connections.

Gather the necessary tools – Ensure you have the appropriate tools to disconnect the connectors safely. This may include wrenches, screwdrivers, and any other specialized tools recommended by Chevy Captiva repair manuals.

Disconnect the electrical connectors – Start by carefully disconnecting the electrical connectors. These connectors supply power to the fuel system, so it is important to disconnect them first. Follow the wires from the fuel tank to locate the electrical connectors and unplug them.

Label the wires – Before proceeding, clearly label or mark the wires to ensure proper reconnection during reassembly. This will help you identify which wires go where, making the reassembly process easier and preventing misconnections.

Disconnect the vacuum connectors – Next, locate the vacuum connectors, which are responsible for maintaining the fuel system's pressure and preventing leaks. Again, follow the fuel lines to find the vacuum connectors and carefully disconnect them.

Clean the connectors – Once all the connectors are disconnected, clean them to remove any dirt, debris, or corrosion. This step is important to ensure proper connections and prevent future issues. Use a suitable cleaning agent and a clean cloth to wipe down the connectors.

Store the connectors safely – As you work, keep the disconnected connectors organized and stored safely to avoid misplacing them. Place them in a secure location where they won't be damaged or lost during the rest of the fuel tank replacement process.

Remember, working with fuel systems can be dangerous, so it is essential to take appropriate safety precautions. Always refer to the Chevy Captiva service manual for detailed instructions and safety guidelines specific to your vehicle.

Clean mating surface and install a new part

To replace the fuel tank of a Chevrolet Captiva Sport, you will need to clean the mating surface and install a new part. Here is a detailed guide on how to do this:

Clean the mating surface

Before installing the new fuel tank, it is important to clean the mating surface thoroughly. This will ensure that the new part adheres properly and creates a tight seal. Use a suitable cleaning agent to remove any dirt, grease, or debris from the mating surface. It is also recommended to inspect the surrounding components for any signs of damage or corrosion. Look for the fuel tank retaining straps and replace them if necessary. Corroded or damaged retaining straps can compromise the integrity of the fuel tank and pose a safety hazard.

Install a new part

When you are satisfied with the cleanliness of the mating surface, it's time to install the new fuel tank. This process can be challenging, as fuel tanks are large, cumbersome, and heavy. It is recommended to have an assistant to help with the installation process to prevent injury and damage to the vehicle. Carefully lift the new fuel tank into place, ensuring it is securely mounted to the bottom rear of the vehicle. Connect all the necessary electrical and vacuum connectors to the new fuel tank. Once the new fuel tank is in place, perform a self-diagnostic test to ensure there are no leaks or other issues.

If you feel that you are unqualified for this task, it is best to leave it to a professional technician. Fuel tank replacement involves working with electricity and fuel, so proper knowledge of safety procedures is crucial.

Refuelling safety precautions

Turn off your engine: Always turn off your vehicle's engine before refuelling. Engines produce heat, sparks, and electromagnetic radiation, which can potentially ignite gasoline vapors. This is a crucial step to prevent any accidents or fires.

Stay with the vehicle: Do not leave the vehicle unattended while refuelling. Stay by the pump and remain alert to address any issues promptly. Pay close attention during the refuelling process to identify any potential hazards.

No smoking or open flames: Keep sparks, flames, and smoking materials away from the fuel pump. Gasoline and diesel fumes are highly flammable, and even a small spark can lead to a disaster. Avoid any activities that may create a source of ignition.

Avoid using your cell phone: Using your cell phone can create a distraction and lead to unsafe practices. By staying focused on the task, you can ensure a safe refuelling process and properly secure any loose caps or clean up any spills.

Use approved containers: If you need to store diesel fuel in a container, use only approved containers that meet OSHA diesel fuel storage regulations. Never use makeshift containers, and always store fuel away from any potential sources of ignition.

Do not overfill the tank: Avoid overfilling or topping off the fuel tank. Gasoline expands with temperature changes, and overfilling can cause fuel to spill out, posing a safety hazard and environmental concerns. Fill the tank to the recommended level and stop when the pump nozzle automatically shuts off.

Be cautious with fuel spills: If a fuel spill occurs, inform the gas station attendant immediately. Fuel spills are hazardous to the environment and can pose a fire risk. Do not attempt to clean up the spill yourself unless you are trained to do so.

Dispose of waste properly: If you use disposable gloves or paper towels during refuelling or spill cleanup, dispose of them in designated trash bins. Do not leave them near the fueling area as they can become fire hazards.

Keep children away: Ensure that children do not handle the fuel pump or come into close contact with the fuel.

Follow instructions: Read and adhere to all the instructions provided on the fuel pump island to ensure a safe refuelling process.

Symptoms of a bad fuel tank

A bad fuel tank in your Chevy Captiva can cause a variety of issues and symptoms. Here are some key indicators and symptoms to watch out for:

Check Engine Light

The "check engine" light coming on is one of the most common symptoms of a faulty fuel tank. This warning light illuminates when there is a problem with the engine or emissions system. In the case of a bad fuel tank, the check engine light may be triggered by a failed EVAP system test, indicating an issue with the evaporative emissions control system.

Popping Sound and Check Engine Light

In some Chevy Captiva models, a popping sound may accompany the check engine light. This sound is caused by the leak detection pump continuously attempting to pressurize the fuel tank. The continuous pressurization efforts result in a distinctive popping noise.

Difficulty Starting the Engine

A bad fuel tank can cause difficulty in starting the engine. This is often due to issues with fuel delivery and pressure. Corrosion, debris, or rust inside the fuel tank can disrupt the normal fuel delivery process, making it challenging to start the engine.

Rough Idle and Poor Fuel Mileage

A faulty fuel tank may lead to a rough idle, which is when the engine runs unevenly at a low speed or while the vehicle is stationary. This can be caused by insufficient fuel delivery or contamination in the fuel. Poor fuel mileage, or decreased fuel efficiency, can also be a symptom of a bad fuel tank. This is often due to a clogged or malfunctioning fuel system, impacting the amount of fuel delivered to the engine.

No Visible Damage but Internal Corrosion

In some cases, a fuel tank may be corroded to the point of failure, but the external tank shows no apparent damage. However, upon inspection, the inside of the fuel tank will be found to have rust or corrosion. This internal damage can cause rust flakes and debris to contaminate the fuel, leading to further issues with the fuel delivery system.

Frequently asked questions