Fuel Tank Removal and Installation

NOTE: The Viper Coupe does not have a Fuel Tank Closeout Panel. To remove the fuel tank, a hole will have to be cut in the trunk pan. Refer to the template that comes with the closeout panel and, using a suitable cutting tool, cut the trunk pan. For installation of panel, refer to Closeout Panel Installation Procedures

REMOVAL
1. Release fuel system pressure.
2. Drain the fuel tank before removing it from the vehicle.

Fig. 25 Fuel Tank Closeout Panel:

3. Disconnect positive battery cable at the PDC. The trunk will have to have a closeout panel cut into it for servicing the fuel tank (Fig. 25).
4. Remove spare tire. Remove spare tire tool kit.
5. Remove trunk trim panels from trunk area.
6. Remove the radio amplifier and bracket.
7. Remove trunk carpet.
8. Cut closeout panel hole for fuel tank.

Fig. 27 Fuel Filler Neck Removal/Installtion:

9. Remove Fuel Filler neck mounting screws (Fig. 27).
10. Reach inside and disconnect the filler tube at the fuel tank.
11. Remove the rubber vapor recirculation line at the fuel filler tube.
12. Disconnect the EVAP canister supply line at the ORVR control valve.
13. Reach inside and remove the two fuel tank attaching bolts.
14. Slide the fuel tank rearward and disconnect the fuel line at the fuel pump module and the electrical connector. To absorb any fuel still in the tubes, wrap shop towels around ends of fuel supply line.
15. Remove fuel tank from vehicle.

INSTALLATION
1. Install fuel tank half way through closeout opening.
2. Connect fuel pump module electrical connector to fuel pump module.
3. Connect the EVAP canister supply line at the ORVR control valve.
4. Connect fuel line to the fuel pump module. Refer to Quick-Connect Fittings .
5. Slide tank forward.
6. Reach inside and connect the filler tube at the fuel tank. Tighten clamp.
7. Install the rubber vapor recirculation line to the fuel filler tube.
8. Position fuel filler neck in opening in body panel. Install and tighten mounting screws (Fig. 27).
9. Reach inside and install the two fuel tank attaching bolts. Tighten to 20 Nm (177 in. lbs.) torque.
10. Connect positive battery cable at the PDC.
11. Fill fuel tank.
12. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
13. Install closeout panel in trunk.
14. Install trunk carpet.
15. Install the amplifier and bracket.
16. Install trunk trim panels into trunk area.
17. Install spare tire tool kit. Install spare tire.
18. Clean trunk area.