Replacing The Fuel Tank In Your '78 Camaro

Replacing the fuel tank in a 1978 Camaro is a complex process that requires careful attention to safety. It is recommended to have a second person to help with the task. The first step is to disconnect the battery and fuel line, completely draining the old gas tank in a well-ventilated area without any open flames. Next, the filler neck should be disconnected from behind the license plate mount. After unbolting the rear strap mounts, the old tank can be dropped and removed. It is important to note that some components, such as the exhaust, may need to be removed as well. When installing the new fuel tank, it is crucial to follow the manufacturer's instructions and ensure all connections are secure before adding fuel.

Disconnect the battery and fuel line, then drain the old gas tank

Disconnecting the battery and fuel line and draining the old gas tank is the first step in replacing the fuel tank in a 1978 Camaro. Here is a detailed guide on how to do this:

Disconnect the battery

Before you begin any work on your Camaro, it is important to disconnect the battery to avoid any potential electrical hazards. Locate the negative battery terminal, which is usually marked with a "-" symbol, and use a wrench to loosen the nut that holds the cable in place. Once it is loose, carefully remove the cable from the battery post. Make sure that you do not let the cable touch any metal parts of the car, as this could cause a short circuit.

Disconnect the fuel line

The next step is to disconnect the fuel line. The fuel line is usually located near the fuel tank, which is at the rear of the car. Use a wrench to loosen the nut that secures the fuel line to the tank. Again, be careful not to let the fuel line touch any metal parts of the car, as this could create a spark and cause a fire. Once the nut is loose, carefully remove the fuel line from the tank.

Drain the old gas tank

Place a fuel container under the fuel tank to catch the drained fuel. You can use a hand pump to siphon the fuel out of the tank, or you may find it easier to use an electric pump. Be very careful during this process, as gasoline is highly flammable. Make sure you are in a well-ventilated area and avoid any open flames or ignition sources. It is also a good idea to wear safety goggles and gloves to protect your eyes and hands from the fuel.

Once the fuel tank is empty, you can proceed to the next steps of the fuel tank replacement process, which include removing the filler neck, unbolting the rear strap mounts, and sliding the old tank out of the car. These steps are detailed on several online forums dedicated to Camaro maintenance and repairs.

Disconnect the filler neck from behind the license plate mount

Disconnecting the filler neck from behind the license plate mount is a crucial step in replacing the fuel tank in a 1978 Camaro. Here is a detailed, step-by-step guide to help you through the process:

Firstly, it is important to ensure your safety. Make sure you wear protective gear, including gloves and eye protection, and work in a well-ventilated area.

Now, to begin the process:

• Locate the filler neck: The filler neck is the component that connects the fuel filler tube to the fuel tank. It is usually found behind the license plate mount.
• Access the filler neck: To access the filler neck, you will need to remove the license plate and any surrounding trim or panels that may obstruct your access. This will give you the necessary space to work.
• Disconnect the filler neck: Once you have clear access to the filler neck, you will need to disconnect it from the fuel filler tube and the fuel tank. This may involve removing clamps, hoses, or other fasteners that secure the filler neck in place. Be sure to have a container or tray ready to catch any residual fuel that may leak out during this process.
• Handling the fuel: It is important to handle the fuel carefully and avoid any open flames or ignition sources. Ensure you have a safe and proper way to dispose of or store any fuel that is drained or spilled during this process.
• Detaching the filler neck: The specific method for detaching the filler neck may vary depending on your Camaro's model and year. In some cases, you may need to twist, lift, or pull the filler neck to detach it. Be careful not to use excessive force, as this may damage the surrounding components or the filler neck itself.
• Protecting the filler neck: After successfully detaching the filler neck, it is important to protect it from damage during the rest of the fuel tank replacement process. Set it aside in a safe place, away from any potential hazards.

Remember to refer to your Camaro's service manual or seek guidance from a qualified mechanic if you encounter any difficulties or uncertainties during this process. Working with fuel systems can be dangerous, so always prioritize your safety and the safety of those around you.

Unbolt rear strap mounts and remove the old tank

To unbolt the rear strap mounts and remove the old tank from your 1978 Camaro, follow these steps:

First, empty the tank. The less fuel in the tank, the easier it will be to remove. Siphon the fuel out or disconnect the outlet hose at the sending unit or fuel pump inlet. You can then lightly pressurise the tank into a gas can to pour the fuel into another vehicle or container. Remember to do this in a well-ventilated area with no open flames or ignition sources present.

Next, spray the rear strap mount bolts and nuts with a penetrating lubricant like PB Blaster. Leave this overnight to loosen and lubricate the bolts.

Now, disconnect the fuel gauge wire, which is located behind the fuel neck in the trunk. It should be a tan wire. Also, remove the ground wire on the trunk floor brace in front of the tank on the right side.

Cut the rubber hose from the sending unit to the fuel line on the frame.

Remove the nuts and bolts holding the rear strap mounts in place. You may need an open-ended wrench or a deep socket to do this. With these removed, pull the straps down and lower the tank. You may need an extra pair of hands for this part.

Finally, carefully remove the tank from the Camaro.

Apply weatherstrip cement to the new tank

To apply weatherstrip cement to the new tank, you can use 3M Super Weatherstrip Adhesive 08001 (yellow) or 08008 (black). This will be used to attach the antisqueak strips to the tank.

Firstly, remove the new tank from its packaging and unwrap it. Then, apply the weatherstrip cement to the tank. Take the antisqueak strips and apply them to the tank, pressing them into place.

This step is part of a larger process of replacing the fuel tank in a 1967-1969 Camaro. Other steps include disconnecting the battery, draining the old gas tank, disconnecting the filler neck, and unbolting the rear strap mounts.

Insert the new tank, secure it with bolts, and connect the filler tube

Now that the old fuel tank has been removed, it's time to install the new one. This process will involve inserting the new tank, securing it with bolts, and connecting the filler tube. Here are the steps you need to follow:

Inserting the New Fuel Tank

Before you begin, make sure the new tank is properly wrapped and protected during shipment. Unwrap the tank and apply weatherstrip cement to it. You can use products like 3M Super Weatherstrip Adhesive (in yellow or black). Press the antisqueak strips into place.

Next, soak the rubber sending unit o-ring in clean motor oil to make installation easier. Place the o-ring in the sending unit hole. Insert the sending unit into the hole, with the fuel line facing the front passenger side corner of the tank.

Now, insert the retaining cam (lock ring) that comes with the tank into the retaining groove. Use a retaining cam tool to press down and turn the lock ring. Stretch the sending unit wire across the top of the tank and secure it with black tape to prevent chafing during installation.

Securing the Fuel Tank with Bolts

Pre-bent straps are designed to fit the strap groove in the tank. Insert the new strap from the front, hooked-end first, into the slot behind the rear axle. Insert the sheet metal screws through the rear holes to retain the straps.

Lift the tank into place, being careful not to pinch the sending unit wire. Pull the strap up and insert the retaining bolts. Secure them with the provided nuts.

Connecting the Filler Tube

With the tank in place, you can now attach the filler tube. Connect the filler tube through the trunk floor to the stub neck behind the license plate access.

Now that the new fuel tank is installed, you can move on to the final steps of the replacement process, such as connecting the sending unit wiring and double-checking all filler hose and fuel line connections. Remember to use a proper vented gas cap and then you're ready to add fuel and get back on the road!

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