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    Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

    Tank Assembly

    Print

    REMOVAL & INSTALLATION



    Cirrus, Stratus, Sebring Convertible and Breeze

    See Figures 1, 2, 3 and 4


    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

    1. Properly relieve the fuel system pressure, as outlined earlier in this section.
    2.  
    3. Disconnect the remote negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
    4.  
    5. On all of these models, except the 1998 Sebring convertible, disengage the fuel pump wiring jumper from the main body harness, located in the trunk. The 4-pin connector is located under the trunk compartment floor mat to the left side, near the base of the shock tower. Locate the body grommet for the jumper near the base of the rear seat.
    6.  
    7. On the 1998 Sebring convertible, remove the rear seat. Refer to Body & Trim . Disengage the fuel pump module wiring connector from the main body harness.
    8.  
    9. Push the body grommet out and pass the wiring completely through the hole.
    10.  
    11. Release the pressure in the fuel tank, by slowly removing the fuel filler cap.
    12.  
    13. Raise and safely support the vehicle.
    14.  
    15. Place a transmission jack or equivalent support fixture under the fuel tank.
    16.  



    Click image to see an enlarged view

    Fig. Fig. 1: Location of the fuel tank drain plug

    1. Place an approved fuel storage container, with at least a 16 gallon capacity, under the drain plug located on the bottom left edge of the fuel tank. Remove the drain plug and allow the fuel to empty into the container.
    2.  

    After the tank is finished draining, there will still be approximately 1-2 gallons of fuel remaining.

    1. Install the drain plug and tighten to 32 inch lbs. (4 Nm).
    2.  



    Click image to see an enlarged view

    Fig. Fig. 2: Loosen the hose clamp and disconnect the filler hose from the fuel tank

    1. To reduce fuel splash, carefully disconnect the rubber filler hose from the fuel tank, as there may still be some residual fuel in the filler hose.
    2.  

    Wrap shop towels around the fuel hoses to catch any gasoline that may spill when the lines are disconnected.

    Click image to see an enlarged view

    Fig. Fig. 3: Disconnect the fuel lines from the fuel pump module

    1. Disengage the quick-connect fuel tubes from the fuel pump module. If necessary, refer to the quick-connect fitting information earlier in this section.
    2.  
    3. Disconnect the vapor line from the fuel tank-mounted rollover valve. The rollover valve is located at the rear of the fuel tank and connects to the vapor line with a rubber hose.
    4.  
    5. With the tank supported by a transmission jack, or equivalent, remove the bolts and fuel tank mounting straps. Start with the passenger side mounting strap first.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 4: Disengage the electrical connector from the leak detection pump

    1. On 1998 Cirrus, Stratus and Breeze models only, perform the following steps:
      1. Lower the fuel tank just enough to disconnect the purge and vent hoses.
      2.  
      3. Disconnect the hoses from the EVAP canister.
      4.  
      5. Unplug the electrical connector from the Leak Detection Pump (LDP).
      6.  

    2.  
    3. Remove the fuel tank from the vehicle. Slide the fuel tank forward during removal to enable the filler neck to clear the rear suspension crossmember.
    4.  

    To install:
    1. Position the fuel tank onto the transmission jack.
    2.  
    3. Raise the tank into position. Connect the vapor line to the rollover valve.
    4.  
    5. On 1998 Cirrus, Stratus and Breeze models only, perform the following steps:
      1. Connect the wiring harness to the LDP.
      2.  
      3. Connect the hoses to the EVAP canister.
      4.  
      5. Connect the purge and vent hoses.
      6.  

    6.  
    7. Connect the chassis fuel tube to the fuel filter. If necessary, refer to the quick-connect fitting information earlier in this section.
    8.  
    9. Connect the filler hose to the fuel tank inlet. Tighten the hose clamp to 25-31 inch lbs. (3-3.5 Nm).
    10.  
    11. Install the fuel pump module wiring harness grommet into the body.
    12.  
    13. Position the fuel filter and tank straps. Install the front bolts first, then the rear bolts. Tighten the fuel tank strap bolts to 21 ft. lbs. (28 Nm). Check to make sure that the tank straps are not twisted or bent. Remove the transmission jack.
    14.  
    15. Carefully lower the vehicle.
    16.  
    17. Attach the fuel pump module electrical connector.
    18.  
    19. On 1998 Sebring convertible models, install the rear seat.
    20.  
    21. Fill the fuel tank, install the filler cap, then connect the negative battery cable.
    22.  


    CAUTION
    When performing the ASD fuel system test, the ASD relay will remain energized for either 7 minutes, until the test is completed, or until the ignition switch is turned to the OFF position.

    1. Pressurize the fuel system using the Chrysler DRB, or equivalent scan tool, to perform the ASD fuel system test. Check the fuel system for leaks.
    2.  

    Sebring Coupe and Avenger

    See Figures 5 and 6

    1. Properly relieve the fuel system pressure, as outlined earlier in this section.
    2.  
    3. Drain the fuel from the fuel tank into an approved container.
    4.  
    5. Raise the vehicle and support it safely.
    6.  
    7. Disconnect the return hose and high pressure hose from the fuel pump assembly.
    8.  
    9. Detach the electrical connectors at the pump module and fuel gauge sending unit.
    10.  


    CAUTION
    Cover all fuel hose connections with a shop towel, prior to disconnecting, to prevent a splash of fuel which could be caused by residual pressure remaining in the fuel line.

    1. Disconnect the filler and vent hoses.
    2.  
    3. On 1998 models only, disconnect the liquid separator and leveling valve assembly hoses.
    4.  
    5. Remove the fuel tank filler tube protector.
    6.  
    7. Place a transmission jack, or equivalent support fixture, under the center of the fuel tank and apply a slight upward pressure. Remove the fuel tank strap retaining nut or tank retaining nuts, as applicable.
    8.  
    9. Lower the tank slightly and disconnect any remaining electrical or hose connectors at the fuel tank.
    10.  
    11. Remove the fuel tank from the vehicle.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 5: Fuel tank assembly-1995-97 models



    Click image to see an enlarged view

    Fig. Fig. 6: Fuel tank assembly-1998 models

    To install:
    1. Install the fuel tank onto the transmission jack. Raise the tank in position under the vehicle. Leave enough clearance to attach the electrical and hose connections to the top of the fuel pump.
    2.  
    3. Connect the return hose and high pressure hose to the fuel pump.
    4.  
    5. Attach all other connections to the top of the tank.
    6.  
    7. Raise the tank completely and position the retainer straps around the fuel tank, if equipped. Install new fuel tank self-locking nuts and tighten to 19-22 ft. lbs. (25-30 Nm).
    8.  
    9. On 1998 models only, connect the liquid separator and leveling valve assembly hoses.
    10.  
    11. Install the vent hose and filler hose.
    12.  
    13. Install the fuel tank filler tube protector and install the retainers.
    14.  
    15. Carefully lower the vehicle and fill the fuel tank.
    16.  
    17. Install the filler cap, then connect the negative battery cable.
    18.  
    19. Check the fuel pump for proper pressure and inspect the entire system for leaks.
    20.  

     
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