Fuel Tank - Removal

REMOVAL






NOTE: The trunk panel will have to be cut to remove the fuel tank.

1. Release fuel system pressure, Service and Repair.
2. Remove the battery cover and disconnect negative battery cable.





3. Put access panel in place and scribe the outline of the panel. Mark the hole for the rivet that hold the panel in place.





4. Remove the panel and scribe a line about a 1/2 inch in from the panel outline.
5. Cut closeout panel hole for fuel tank.





6. Continue to cut along the scribed mark.





7. Remove closeout panel.





8. Drill holes (17 holes).





9. Remove the convertible top fasteners (15 nuts).





10. Lift the top up and disconnect the heated back glass electrical connector from both sides of the glass.
11. Pull top forward and out of the way.
12. Roll deck lid carpet forward and out of the way.





13. Remove the 4 rivets from the fuel pump module cover.






NOTE: Be careful the sealer on the cover will make it difficult to remove the cover.

14. Using a scraper or long knife cut the sealer under the cover to remove it from the vehicle.





15. Remove the foam block from the top of the fuel pump module.





16. Clean the area round the fuel pump module.
17. Mark fuel pump module location on tank.





18. Unlock and disconnect the electrical connector from the fuel pump module.
19. Disconnect the fuel line, wrap shop towels around ends of fuel supply line.





20. Use Special Tool #6856 to remove fuel pump module locknut.
21. Lift module up to remove being careful not to spill the residual fuel that is left in it. The float arm of the level sensor catches on the inside of the fuel tank while removing the module. Tilt the module assembly to one side while removing it. Discard old seal.





22. Drain the fuel tank through the fuel pump module hole.
23. Raise and support the vehicle.
24. Remove the right rear tire.
25. Remove the right rear splash shield, Splash Shield - Removal.





26. Remove the fuel filler tube from fuel tank.





27. Disconnect the vapor line at fuel filler tube.
28. Remove the fastener for fuel tank strap.
29. Lower vehicle.





30. Remove the left side fuel tank strap nut and remove the strap.





31. Disconnect the ground strap from frame.





32. Disconnect the LDP electrical connector from pump.





33. Remove the liquid separator from the top of the EVAP canister.





34. Pull wiring harness for heated back glass down and out of the way from the top of the fuel tank.






NOTE: You may have to trim some of the trunk panel to make room for removal of fuel tank.

35. Pull fuel tank to the rear of vehicle.





36. Disconnect the vapor lines from the top of the fuel tank.





37. Remove the fuel tank from vehicle.
38. Clean vehicle.





39. Make sure that the fuel tank heat shield is not damaged.