L. Install Fuel Tank - Coupe
NOTE:Fuel tank installation requires the use of P/N CAAP9986 repair package.
1. Place the fuel tank heat shield into position.
2. CAUTION:
Make sure the electrical connector and fuel hoses are accessible through the fuel pump access hole before installing the fuel tank.
3. Install the mounting bolt at each end of the fuel tank strap. Tighten the strap bolts to 175 in. lbs. (20 N.m). Access the bolts through the rear wheel openings (Figure 24).
4. Install a new fuel tank pump module seal (P/N 52018808) into the opening on the fuel tank.
5. Using a twisting motion, slide the fuel pump module into the tank opening and start the fuel pump module lock ring by hand.
CAUTION:
The fuel pump module is spring loaded against the bottom of the fuel tank. Some downward force will have to be applied to fully seat the module before installing the lock ring.
6. Using Special Tool # 6856 - Fuel Pump Spanner Wrench, tighten the lock ring to 34 ft. lbs. (25 N.m) (Figure 25).
7. Connect the fuel filler hose and vent hose.
8. Use the following procedure to connect the fuel tube quick connect fitting:
a. Using a clean lint free cloth, clean the fuel tube nipple and retainer.
b. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil.
c. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard.
d. The plastic quick-connect has windows in the side of the casing. When the fining completely attaches to the fuel tube, the retaining locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Figure 39). Do not rely upon the audible click to confirm a secure connection. Pull back on the quick-connect to ensure a secure connection.
9. Connect the fuel pump module electrical connector.
10. Connect the rollover valve hose at the fuel pump module.
11. Connect the vent hose to the filler tube (Figure 19).
12. Using a twisting motion, install the aluminum fuel filler cap cover onto the fill tube.
13. Install the fuel filler cap cover screws.
14. Install the fuel pump module access cover using four (4) supplied rivets (P/N 06034578).
CAUTION:
Rivet gun (P/N W-AK17SACH) requires the use of the provided gold color nose piece (P/N W-202145) to correctly install the fuel pump module access cover rivets (P/N 06034578).
15. Place the new fuel tank access panel over the access hole and drill two guide holes in the lower comers of the access panel (Figure 40). Use a 1/4 inch diameter drill bit and set the drill stop to 3/8 inch or damage to components behind the panel could result.
16. Drill two 1/4 inch diameter holes in the upper corners using the holes in the access panel as a guide (Figure 40).
17. Remove the access panel and apply a 1/2 inch bead of Mopar Silicone Sealant (or equivalent) around the entire outer edge of the access hole.
18. Position the access panel over the access hole and install the four corner guide rivets using the air rivet gun.
NOTE:
Rivet gun (P/N W-AK175ACH) requires the use of the provided gold color nose piece (P/N W-202145) to correctly install the rivets (P/N 06034578). If installing original access panel, rivets (P/N 06034578) can be ordered separately. Do not substitute rivets.
9. Drill 20 1/4" holes as shown in Figure 40 and install the rivets using rivet gun.
20. Wipe off any excess Silicone sealant from the trunk side perimeter of the access panel.
21. Install the upper trunk lining (Figure 23).
22. Install the lower trunk lining (Figure 22).
23. Install the radio amplifier and bracket onto the left side corner of the trunk.
24. while one technician holds the liftgate, remove the left lower liftgate prop rod support clip and disconnect the lower end of the lifigate prop rod.
25. Slide the left side quarter trim panel into place and reconnect the prop rod and support clip.
26. Repeat steps 24 and 25 to install the right side quarter trim panel.
27. Install all screws on the left and right rear quarter trim panel (Figure 21).
28. Connect the liftgate ajar switch electrical connection.
29. Install the trunk rear trim panel (Figure 20).
30. Clean trunk floor and install tool kit.
31. Install spare tire assembly.
32. Continue with Section "M - Install Differential."