This is a general overview. Consult a repair manual specific to your 1980 Pontiac Trans Am for detailed instructions, diagrams, and torque specifications. These manuals are invaluable and will show you precisely what to do and avoid.
Safety First!
* Disconnect the battery's negative terminal. This prevents accidental sparks.
* Work in a well-ventilated area. Gasoline fumes are highly flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
* Use proper jack stands. Never work under a car supported only by a jack.
Steps (General Outline - Refer to your repair manual!):
1. Drain the fuel tank: This is crucial. Use a fuel pump or siphon to remove as much fuel as possible. You may need to disconnect the fuel lines (see below) for complete drainage. Dispose of the fuel properly – at a gas station or recycling center.
2. Disconnect the fuel lines: Carefully disconnect the fuel supply and return lines. These lines are under pressure, so take precautions to avoid spills. You might need special fuel line disconnect tools. Be prepared for a small amount of fuel to spill, despite your best efforts. Have rags ready.
3. Disconnect the fuel sender: This is the unit inside the tank that measures the fuel level. It's usually connected electrically and may also have a ground wire.
4. Disconnect the vent line: This allows for pressure equalization in the tank.
5. Remove the filler neck: This is the tube connecting the tank to the gas cap. Depending on the configuration, it might require bolts, clamps, or other fasteners.
6. Lower the gas tank: This is often the most difficult step. You will likely need to remove some surrounding components, like exhaust parts or body panels, to gain access. You'll likely need to loosen, and possibly remove, straps or bolts securing the tank to the vehicle's frame. Use jack stands or a support system to lower the tank safely.
7. Install the new gas tank: Reverse the removal process, carefully connecting all lines and components in the proper order.
8. Reconnect the fuel lines and ensure tight seals: Double-check everything for leaks.
9. Reconnect the fuel sender, vent line, and filler neck.
10. Reconnect the battery:
11. Test for leaks: Before driving, check all connections for leaks and carefully inspect the new tank for any signs of leakage.
Important Considerations:
* Rust and corrosion: The tank straps and surrounding areas might be rusted. Use penetrating oil to loosen fasteners.
* Bolts and fasteners: Many fasteners are likely to be rusted or seized. Use caution to avoid damaging them.
* Fuel lines and seals: Replace any deteriorated fuel lines or seals. Never reuse old components.
This job is complex and potentially dangerous. Again, a repair manual specific to your vehicle is essential. If you are not comfortable performing this repair yourself, take your car to a qualified mechanic. The cost of professional repair is far less than the potential costs of a fire or injury.
