G. Fuel Tank Removal - Coupe

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 fliel pressure release hose, special tool # C-4799-1, into an approved gasoline container. Connect the other end of the hose 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 # C-4799-1.

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

3. Open the liftgate and remove the spare tire and tool kit.





4. Remove the trunk rear trim panel (Figure 20).





5. Remove all of the screws from the left and right trim panels (Figure 21). Do not attempt to remove the panels at this time.

6. Move the driver and passenger seats to their forward-most position.

7. While an assistant holds the liftgate, remove the lower liftgate support clips on the right side and disconnect the prop rod. Then slide the right trim panel out of the vehicle.

8. Temporarily reattach the right side liftgate prop rod.

9. Disconnect the ajar switch from the left prop rod.

10. While an assistant holds the liftgate, remove the lower liftgate support clips on the left side and disconnect the prop rod. Then slide the left trim panel out of the vehicle.

11. Temporarily reattach the left side liftgate prop rod.

12. Remove the radio amplifier located at the left corner of the trunk.

13. Remove the radio amplifier bracket mounting bolts and pull bracket aside.





14. Remove the lower trunk lining (Figure 22).





15. Remove the upper trunk lining (Figure 23).

16. Remove the fuel pump module access cover by drilling out the four rivets (Figure 23).

17. ^ If the vehicle has not had a fuel tank access panel installed during a previous service repair, continue with Step 18 of this procedure.

^ If the vehicle has had a fuel tank access panel previously installed, remove the access panel using the following procedure:

a. Drill out all rivets that hold the access panel to the trunk wall.

b. Using a wide gasket scraper, carefully pry the access panel from the trunk wall.

NOTE:
Save the access panel for installation after repairs are complete.

c. Continue with Step 25 of this procedure.

18. Mask off the passenger compartment to avoid dust entering the vehicle interior.

19. Position a new service access panel onto the front of the spare tire opening.

20. Using the access panel as a template, outline the outer edge with a grease pencil.

21. Remove the access panel and measure one inch (25 mm) inward from the line drawn in step 20 and then draw a new line for cutting.

22. Using a cut off wheel and a thin disc, cut along the inside line made in Step 21.

WARNING:
Wear a long sleeve shirt, dust mask and a full face shield when cutting the access panel hole.

CAUTION:
To avoid damage to components behind the panel, do not allow the cutting wheel to penetrate deeper than 1/2 inch (13 mm). The cutting wheel must remain on the inner line made in step 21. The one inch of material must be maintained for proper attachment of the panel rivets during installation of the fuel tank access panel.

23. Remove the panel cut out from the spare tire opening wall and discard it.

24. Using a suitable shop vacuum, clean all dust and debris from trunk area.

CAUTION:
After the panel has been cut, do not apply any weight onto the forward floor pan area.





25. Remove the mounting bolt from each end of the fuel tank strap by accessing the bolt through the wheel well (Figure 24).

26. Remove the fuel filler cap cover screws.

27. Using a twisting motion, remove the aluminum fuel filler cover from the fill tube.

28. Disconnect the fuel tank vent hose from the filler tube (Figure 19).

29. Disconnect the fuel filler hose, fuel line and vent hose from the tank module.





30. Using Special Tool # 6856 - Fuel Pump Module Spanner Wrench, remove the fuel pump module lock ring (Figure 25).

31. Using a twisting motion, remove the fuel pump module from the fuel tank.

CAUTION:
The fuel pump module will have some stored fuel. Have a container ready to store the module in until assembly.

32. Drain the fuel tank using an approved siphoning tank. Refer to the siphoning tank manufacturer's instructions.

33. With the help of an assistant, slide the fuel tank and heat shield out of the new access hole.

CAUTION:
There is limited clearance at the left fuel tank strap attachment. Use care when removing the tank at that position.

34. 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, continue with Section "I - Differential Bracket Repair (Cracks More Than 3/8 inch (9.5 mm)).