Repair Procedure

This bulletin provides the procedure to install an access panel into the trunk for fuel tank replacement.

1. Open hood and disconnect the negative battery cable.

2. Depressurize the fuel pressure using the procedure in the 1998 Viper Service Manual (Publication No. 81-270-8150) page 14-10.

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

4. Remove the tail light trim panel. Do not remove the speakers.

CAUTION:
USE CARE WHEN WORKING WITH TRIM PANELS TO AVOID DAMAGE TO THE PANELS.

5. Remove all screws on the left and right rear quarter trim panels. Do not attempt to remove the panels at this time.

6. While one technician holds the liftgate, remove the lower liftgate support clips on one side and slide the panel out.

7. Attach the liftgate support clip.

8. Repeat steps 6 and 7 on the other side.

9. Remove the amplifier and bracket located on the left side of the vehicle.

10. Remove the bottom trunk carpet panel.

11. Remove the front trunk carpet.

12. Remove the fuel pump module access cover by drilling out the four rivets.

13. Mask off the cockpit area to avoid dust entering the vehicle interior.





14. Position the new service access panel (p/n 04848582AB) into the front of the spare tire opening. Using the access panel as a template and outline the outer edge with a grease pencil (Figure 1).





15. Remove the access panel and measure inwards from the original line 1" and draw a new line for cutting (Figure 2).

16. Cut inside line made in step 15 with a die grinder and thin disk.

CAUTION:
DO NOT PENETRATE DEEPER THAN 1/2 INCH. STAY ON THE INSIDE LINE MADE IN STEP 15, THE ONE INCH OF MATERIAL MUST BE MAINTAINED FOR PROPER ATTACHMENT OF THE PANEL RIVETS DURING INSTALLATION OF THE SERVICE ACCESS PANEL. AFTER PANEL HAS BEEN CUT DO NOT PUT WEIGHT ONTO FORWARD PAN AREA.





17. Drill a 3/4 inch diameter hole in the top panel at each end of the tank for tank strap access (Figure 3).

18. Remove the 13 mm bolt from each end of strap through the holes made in step 17 and remove the tank strap.



19. Remove the fuel filler hose.

CAUTION:
THE FUEL PUMP MODULE WILL HAVE SOME STORED FUEL, HAVE A CONTAINER READY TO STORE THE MODULE IN UNTIL ASSEMBLY

20. Remove the fuel pump module. Drain the fuel from the fuel tank using an approved siphoning tank.

21. With two people, slide the fuel tank out of the new access hole.

CAUTION:
THE LEFT FUEL TANK STRAP ATTACHMENT IS A TIGHT FIT, USE CARE WHEN REMOVING TANK AT THAT POSITION.

22. Install the new tank.

23. Install the fuel tank strap and torque the strap bolts to 20 Nm (177 in. Lbs.).

24. Install the fuel pump module.

25. Install the fuel filler hose and tighten the clamp.

NOTE:
THE SERVICE ACCESS PANEL WILL COME WITH A PRE-DRILLED HOLE IN EACH TOP CORNER. THE 2 ADDITIONAL GUIDE HOLES SHOULD BE DRILLED IN EACH LOWER CORNER.





26. Place the access panel into position on the vehicle and drill 2 additional guide holes through the lower panel and body. Use a 1/4" drill bit and set the drill stop to 3/8" (Figure 4).





27. Remove the panel and apply Mopar Silicone Sealer (p/n 04798408) in large amounts across the 1" marks along the edge cut into the vehicle trunk panel (Figure 5).

28. Position the panel and install the 4 rivets, using an air riveter (PSE - W-AK175), into the pilot holes made in Step 23.





29. Drill the remaining holes and install the rivets using a minimum of 20 rivets (Figure 6).

30. Place a thin film of RTV along the bottom of the plug (p/n 04848881AA) and install into holes cut in Step 17.

31. Install the fuel pump module access cover by installing the four rivets.

32. Install the front trunk carpet.

33. Install the bottom trunk carpet panel.

34. Install the amplifier and bracket located on the left side of the vehicle.

35. While one technician holds the liftgate, remove the lower liftgate support clips on one side and slide the panel in.

36. Attach the liftgate support clip.

37. Repeat procedure for other side.

38. Install all screws on the left and right rear quarter trim panels.

39. Install the tail light trim panel.

40. Install the spare tire and tool kit.

41. Connect the battery negative cable.