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Fuel Tank: Installation

  1. Make sure that the fuel tank heat shield (Figure and Figure ) 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 (Figure ).
  4. Connect the LDP electrical connector to pump (Figure ).
  5. Connect the vapor lines to the tank (Figure ).
  6. Slide tank forward.
  7. Install the liquid separator (Figure ) to the top of the EVAP canister.
  8. Install the left side fuel tank strap nut (Figure ).
  9. Raise vehicle and support.
  10. Install the fuel filler tube to fuel tank (Figure and Figure ).
  11. Connect the vapor line at fuel filler tube (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 the FUEL PUMP MODULE  in this section.
  17. Use Special Tool #6856 to install fuel pump module locknut (Figure ).
  18. Connect fuel line to the fuel pump module. Refer to QUICK-CONNECT FITTINGS  in the Fuel Delivery Section.
  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(R) 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 (Figure and Figure ).
  25. Place fuel pump module cover inplace, apply sealer to the cover and install.
  26. Install the 4 rivets for the fuel pump module cover (Figure and Figure ).
  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 (Figure ) to both sides of the glass.
  31. Roll deck lid carpet back in place.
  32. Install the convertible top fasteners (15 nuts) (Figure and Figure ).
  33. Clean vehicle.
  34. Connect negative battery cable and install the battery cover.
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