The dripping gas tank should always be replaced rather than repaired, as all repair methods eventually lead to a drip in the same spot on the gas tank. In most cases, replacing the gas tank will cost less than repairing it. In addition, most do-it-yourself mechanics can swap out the gas tank in a matter of hours, rather than visiting a professional mechanic or service center.
Tools Used: Hydraulic vehicle jack, Jack stands, Socket set, Wrench set, Flat block of wood, Brass punch
Repair a Dripping Gas Tank
Relieve the fuel system pressure on fuel-injected models. Pull down the carpet on the sides of the trunk, as the inertia switch needed for the procedure is located on different sides of the trunk on different models. Unplug the inertia switch electrical connector, the only electrical connector on the side of the trunk body. Start the vehicle and allow it to run until it stalls.
Raise the rear of the vehicle with the hydraulic jack. Place jack stands under the frame rails on both sides of the car to secure it while changing the gas tank.
Disconnect the negative battery cable from the terminal with a socket wrench.
Unscrew the fuel filler neck bracket bolt attaching the filler neck tube and the breather hose to the gas tank, using a socket wrench. Detach the filler neck and breather hose from the fuel tank.
Disconnect the fuel pump from the fuel tank on vehicles with a chassis-mounted fuel pump. Use a wrench to unscrew the fuel line that connects the fuel pump to the gas tank.
Slide a hydraulic vehicle jack under the gas tank, placing a flat block of wood between the jack and the bottom of the gas tank. Raise the jack until it is supporting the weight of the gas tank.
Unscrew the bolts holding the front end of the fuel tank retaining straps in place. Pivot the straps out from under the fuel tank.
Slightly lower the tank to gain access to the top of the tank. Unplug the electrical harness for the fuel pump. Unscrew the vapor and return lines from the top of the tank with a wrench, then remove the tank completely from the vehicle.
Tap the lock ring holding the fuel pump inside the fuel tank on models with an in-tank fuel pump, using a brass punch. Tap the ring counterclockwise until the pump and sending unit assembly can be pulled from the tank.
Place the locking ring gasket onto the gas tank and insert the fuel pump and sending unit assembly into the replacement fuel tank on models with an in-tank fuel pump. Tap the lock ring clockwise until it is firmly seated onto the gas tank.
Slide the gas tank under the vehicle and raise it slightly with the hydraulic jack. Plug in the electrical harness for the fuel pump. Screw the vapor and return lines to the top of the tank with a wrench.
Raise the tank with the hydraulic jack. Pivot the fuel tank retaining straps under the tank and install the strap retaining bolts.
Connect the fuel line that runs from the gas tank to the fuel pump with a socket wrench on models with a chassis-mounted fuel pump.
Attach the filler neck and breather hose to the gas tank. Screw the fuel filler neck bracket bolt attaching the filler neck tube and the breather hose to the gas tank.
Remove the jack stands from under the vehicle and lower it with the hydraulic jack.
Reconnect the negative battery cable to the battery terminal.
Reconnect the inertia switch electrical connector.
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