F. Fuel Tank Removal - Roadster

1. Remove the fuel filler cap.

2. Release the fuel pressure from the fuel system using the following procedure:

a. Remove the protective cap from the fuel pressure test port located at the rear of the passenger side of the intake manifold.





b. Place the open end of the fuel pressure release hose, special tool number C-4799-1, into an approved gasoline container. Connect the other end of the hose (C-4799-1) to the fuel pressure test port (Figure 16). The fuel pressure will bleed off through the hose into the gasoline container.

NOTE:
Fuel Gauge Kit C-4799-A contains hose C4799-1.

c. Remove the hose and install the protective cap onto the fuel pressure test port.

3. Drain the fuel tank by inserting a 1/4 or 5/16 inch hose from a portable fuel siphoning tank through the fuel filler neck opening into the fuel tank. Refer to the siphoning tank manufacturer's instructions.

4. Remove the spare tire from the trunk.





5. Using a suitable drill with a 1/8 inch (3 mm) drill bit, drill out the rivets that hold the fuel tank access panel to the trunk pan (Figure 17).

6. Remove the access panel.





7. Remove the fuel filler neck mounting screws (Figure 18).





8. Reach through the access panel opening and disconnect the filler tube from the fuel tank (Figure 19).

9. Remove the rollover valve vent tube.

10. Reach through the access panel opening and remove the two fuel tank attaching bolts.

11. Slide the fuel tank rearward and disconnect the fuel line from the pressure regulator.

WARNING:
To absorb any fuel still in the fuel lines, wrap a shop towel around the end of the fuel supply and vapor tubes.

12. Disconnect the fuel pump module electrical connector.

13. Remove the fuel tank from the vehicle and set the tank aside.

WARNING:
Store the fuel tank a safe distance away from the vehicle during the welding process.

14. For vehicles with:

^ Less than 3/8 inch (9.5 mm) cracking on the differential bracket, continue with Section "H - Differential Bracket Repair (Minor Cracks Less Than 3/8 inch (9.5 mm))."

^ More than 3/8 inch (9.5 mm) cracking on the differential bracket, continue with Section "I - Differential Bracket Repair (Cracks More Than 3/8 inch (9.5 mm))."