jackb
11-19-2011, 02:30 PM
I originally did this writeup on the .com site when I removed my tank to do some frame repair and replace the fuel tank holding plate.
How to: Remove and install the fuel tank
Tools: fuel siphon, jack/stands, wrenches, phillips screwdriver, long needlenose, ~2' long piece of 2x4,
Supplies: coolant to refill the system
Time: not too long, depends how fast you work. ~1 hour to a few hours, depending.
Difficulty: Not
1- Jack up the front of the car and PUT IT ON JACK STANDS.
2- Remove the cover panels in the bonnet for the fuel pump and the brake master cylinder.
3- Disconnect the 2 fuel line, fuel pump canon plug, fuel level sender canon plug, fuel fill line hose clamp and fuel vent line hose clamp.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/d.jpg
4- Remove either the pump or level sender and siphon all remaining fuel out of the tank. A little bit of fuel in the tank makes a huge weight difference and really increases the difficulty manhandling the tank around on the way out.
5- Disconnect the coolant lines behind the tank, on the passenger side at the radiator and on the drivers side under the brake master cylinder.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/c.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/b.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/a.jpg
6- Remove the fuel tank holding plate. The tank won't fall. At the 6:00 position on the tank there's a... nub, or round part, does nothing, but on mine there was a ground wire passing by it that was zip-tied to it. Cut the zip tie so you don't break the wire when the tank comes out. You'll see foam between the tank and frame. I used a pair of needlenose pliers and a long flatheat to pull/rip/pry as much as I could out. Not 100% necessary, but it was difficult enough to pry the tank out that I feel like it made a difference.
7- Using the 2x4, wedge it between the body of the car and the top of the tank. Pry the back of the tank down.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/e.jpg
8- Keep at it, and the whole thing will eventually come out. Once it's about halfway out it becomes significantly easier.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/f.jpg
9- Once the back of the tank is on the ground, you can pull it aft and free from under the car.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/g.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/h.jpg
Installation:
1- Scroll up instead of down.
2- To get the tank into place, put it on the ledge in front, push it up as much as you can with your hands, then use a jack to press it in place.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/k.jpg
3- reconnect everything.
4- Fill the tank
3- Refill/bleed the coolant system
How to: Remove and install the fuel tank
Tools: fuel siphon, jack/stands, wrenches, phillips screwdriver, long needlenose, ~2' long piece of 2x4,
Supplies: coolant to refill the system
Time: not too long, depends how fast you work. ~1 hour to a few hours, depending.
Difficulty: Not
1- Jack up the front of the car and PUT IT ON JACK STANDS.
2- Remove the cover panels in the bonnet for the fuel pump and the brake master cylinder.
3- Disconnect the 2 fuel line, fuel pump canon plug, fuel level sender canon plug, fuel fill line hose clamp and fuel vent line hose clamp.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/d.jpg
4- Remove either the pump or level sender and siphon all remaining fuel out of the tank. A little bit of fuel in the tank makes a huge weight difference and really increases the difficulty manhandling the tank around on the way out.
5- Disconnect the coolant lines behind the tank, on the passenger side at the radiator and on the drivers side under the brake master cylinder.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/c.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/b.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/a.jpg
6- Remove the fuel tank holding plate. The tank won't fall. At the 6:00 position on the tank there's a... nub, or round part, does nothing, but on mine there was a ground wire passing by it that was zip-tied to it. Cut the zip tie so you don't break the wire when the tank comes out. You'll see foam between the tank and frame. I used a pair of needlenose pliers and a long flatheat to pull/rip/pry as much as I could out. Not 100% necessary, but it was difficult enough to pry the tank out that I feel like it made a difference.
7- Using the 2x4, wedge it between the body of the car and the top of the tank. Pry the back of the tank down.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/e.jpg
8- Keep at it, and the whole thing will eventually come out. Once it's about halfway out it becomes significantly easier.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/f.jpg
9- Once the back of the tank is on the ground, you can pull it aft and free from under the car.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/g.jpg
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/h.jpg
Installation:
1- Scroll up instead of down.
2- To get the tank into place, put it on the ledge in front, push it up as much as you can with your hands, then use a jack to press it in place.
http://i30.photobucket.com/albums/c348/kaaooga3/dmc/k.jpg
3- reconnect everything.
4- Fill the tank
3- Refill/bleed the coolant system