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Fuel Tank: Installation

WARNING: This page is about a different car, the 2006 Dodge Viper. However, it is still accessible from the selected car via links, so may be relevant.
  1. Make sure that the fuel tank heat shield. See Figure andFigure is not damaged.
  2. Install fuel tank half way through closeout opening, tank may have to be pushed up from underneath to clear the heat shield.
  3. Install electrical wiring harness over the top of the tank and into the hole next to the fuel pump module hole for the heated back glass. See Figure.
  4. Connect the LDP electrical connector to pump. See Figure.
  5. Connect the vapor lines to the tank. See Figure.
  6. Slide tank forward.
  7. Install the liquid separator to the top of the EVAP canister. See Figure.
  8. Install the left side fuel tank strap nut. See Figure.
  9. Raise vehicle and support.
  10. Install the fuel filler tube to fuel tank. See Figure andFigure.
  11. Connect the vapor line at fuel filler tube. See Figure.
  12. Install the fastener for fuel tank strap.
  13. Install the right rear splash shield.
  14. Install the right rear tire.
  15. Lower vehicle.
  16. Install Fuel pump module into tank, refer to FUEL PUMP MODULE 
  17. Use Special Tool #6856 to install fuel pump module locknut. See Figure.
  18. Connect fuel line to the fuel pump module. Refer to STANDARD PROCEDURE - QUICK-CONNECT FITTINGS  .
  19. Connect fuel pump module electrical connector to fuel pump module and lock.
  20. Fill fuel tank.
  21. Connect negative battery cable.
  22. Use the DRBIII® Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  23. Disconnect negative battery cable.
  24. Install the foam block to the top of the fuel pump module. See Figure and Figure.
  25. Place fuel pump module cover in place, apply sealer to the cover and install.
  26. Install the 4 rivets for the fuel pump module cover. See Figure andFigure.
  27. Install closeout panel in trunk, apply sealer to the panel and install with rivets.
  28. Clean trunk area.
  29. Pull top rearward.
  30. Connect the heated back glass electrical connector to both sides of the glass. See Figure.
  31. Roll deck lid carpet back in place.
  32. Install the convertible top fasteners (15 nuts). See Figure and Figure.
  33. Clean vehicle.
  34. Connect negative battery cable and install the battery cover.
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