Here's a general overview of the process. Again, this is not a complete guide and should not be used as a substitute for a professional repair manual or the assistance of a qualified mechanic.
1. Safety First:
* Disconnect the battery's negative terminal. This is crucial to prevent sparks.
* Ventilate the area extremely well. Gasoline fumes are highly flammable and dangerous. Work outdoors or in a well-ventilated garage with proper ventilation.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
2. Preparation:
* Consult a repair manual specific to your 1987 Corvette. This will provide detailed instructions, torque specifications, and diagrams. A Haynes or Chilton manual will be helpful.
* Gather necessary tools: This will likely include various sockets, wrenches, jack stands, jack, fuel line disconnect tools, a fuel pump removal tool (if applicable), possibly a tank strap wrench, and possibly a fuel tank hoist.
* Drain the fuel tank. This is done by carefully opening the fuel filler neck and using a siphon pump or by disconnecting the fuel lines at the tank and letting the fuel drain into appropriately marked containers. *Dispose of the fuel properly according to local regulations.*
3. Removal:
* Raise and support the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
* Disconnect the fuel lines. This requires special care to avoid spilling fuel. Use appropriate tools and rags to catch any drips. The lines may be clamped or have quick-disconnect fittings.
* Disconnect the fuel sending unit electrical connector.
* Disconnect the vent line.
* Remove the tank straps. This may involve removing other components to access the straps.
* Lower the fuel tank carefully. This may require a tank hoist or considerable effort. The tank is heavy and filled with residual fuel.
4. Installation:
* Install the new fuel tank. Make sure it's properly seated and secure.
* Reconnect all fuel lines, vent lines, and the electrical connector. Double-check all connections for tightness and security.
* Reinstall the tank straps.
* Lower the vehicle carefully.
* Reconnect the battery.
* Check for leaks.
5. Final Checks:
* Check for fuel leaks around all connections.
* Start the engine and check for proper fuel pressure.
* Inspect the gauge to ensure accurate fuel level reading.
Strongly Recommended: This process is complex and involves working with potentially hazardous materials. If you lack the experience or tools, take your Corvette to a qualified mechanic for this repair. The cost of a professional repair is far less than the cost of a mistake. The potential for injury or damage is significant.
