Here's a general outline. Consult a repair manual specific to your 1991 Camaro RS for detailed instructions, diagrams, and torque specifications. Repair manuals from Haynes or Chilton are readily available. These instructions are a guide and may vary slightly depending on your specific model and modifications.
1. Preparation:
* Safety First: Disconnect the negative battery cable.
* Gather Tools: You'll need various tools, including wrenches (metric), sockets, ratchet, screwdrivers, jack stands, jack, fuel line disconnect tool, safety glasses, gloves, and possibly a fuel pump removal tool (depending on your access).
* Vehicle Preparation: Securely jack up the car and place it on jack stands. Never work under a car supported only by a jack.
2. Fuel System Disconnection:
* Release Fuel Pressure: This is crucial to prevent fuel spraying. Consult your repair manual for the specific procedure for your vehicle. It often involves turning the ignition key several times until the fuel pump stops running.
* Disconnect Fuel Lines: Carefully disconnect the fuel lines from the tank. Use a fuel line disconnect tool to avoid damaging the lines. Have rags ready to absorb any spilled fuel.
* Disconnect Fuel Sender: Disconnect the electrical connector for the fuel level sender.
* Disconnect Fuel Vapor Line: Disconnect the fuel vapor line (usually a smaller diameter hose).
3. Tank Removal:
* Locate Tank Straps: The gas tank is secured by straps. These straps are usually located under the car near the rear axle.
* Remove Tank Straps: Use the appropriate wrenches or sockets to remove the bolts securing the tank straps.
* Lower the Tank: Carefully lower the tank. You may need to support it with a helper or straps as you disconnect the remaining components.
* Disconnect Filler Neck: Disconnect the filler neck from the tank. This may involve removing bolts or clamps.
* Remove the Tank: Once all connections are disconnected, carefully lower the tank. It may be heavy and awkward, so use caution.
4. Post-Removal:
* Inspect Tank: Inspect the tank for damage before attempting to reinstall it.
* Clean Area: Clean the area around the tank before reinstalling.
5. Reinstallation (Reverse Order):
Reinstallation is the reverse of the removal process. Make sure all connections are secure, and all bolts are properly tightened to the specified torque.
Important Considerations:
* Fuel Spillage: Be extremely careful to avoid spilling fuel. Gasoline is highly flammable and can cause serious injury or damage.
* Repair Manual: A repair manual is absolutely essential for this procedure. It will provide specific details, diagrams, and torque specifications for your vehicle.
* Safety: Always prioritize safety. Wear appropriate safety glasses and gloves. Work in a well-ventilated area.
* Professional Help: If you're not comfortable performing this task yourself, consider taking your car to a qualified mechanic.
This is a complex procedure. Improperly performing this task could lead to fuel leaks, fire hazards, and damage to your vehicle. Refer to a repair manual for your specific 1991 Camaro RS for detailed, accurate instructions. If you are unsure about any step, consult a professional mechanic.
