Chrysler Neon 1995-1999 Repair Guide

Tank Assembly

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Draining the fuel tank

See Figures 1 and 2


CAUTION
You MUST relieve the fuel system pressure before servicing the fuel system components. Service the vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle.

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure, as outlined earlier in this section.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. For 1995 vehicles, remove the rubber cap from the drain tube. The tube is located on the rear of the fuel tank. Connect either a portable holding tank or a siphon hose to the drain tube.
  8.  



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Fig. Fig. 1: Fuel tank drain tube connection location-1995 vehicles

  1. For 1996-99 vehicles, remove the quick-connect cap from the drain port. The drain port is located on the rear top of the fuel tank. Push a siphon hose into the drain port.
  2.  



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Fig. Fig. 2: Location of the fuel tank drain port-1996-99 vehicles

  1. Drain the fuel tank into the holding tank or a properly labeled GASOLINE safety container.
  2.  

REMOVAL & INSTALLATION



See Figures 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel tank into an approved container.
  8.  

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

  1. Detach the fuel pump module electrical connector.
  2.  



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Fig. Fig. 3: Location of the fuel pump module electrical connector-1995 vehicle shown



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Fig. Fig. 4: Unplug the fuel pump module electrical connector-1996-99 vehicles

  1. Disconnect the quick-connect fuel tubes from the fuel pump module. Disconnect the fuel supply tube from the chassis tube. If necessary, refer to the quick-connect fitting information earlier in this section.
  2.  
  3. Support the fuel tank securely with a transmission jack. Loosen the tank mounting straps, then lower the tank slightly.
  4.  
  5. Disconnect the fuel filler tube and filler vent tube from the filler hose at the fuel tank.
  6.  



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Fig. Fig. 5: Disconnect the fuel filler and vent tubes from the filler hose from the tank-1995 vehicles



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Fig. Fig. 6: Fuel filler tube and vent tube locations-1996-99 vehicles

  1. Disconnect the fuel filler vapor relief tube from the tee connecting it to the tank vapor relief tube and EVAP canister tube.
  2.  
  3. Detach the vapor line from the EVAP canister tube.
  4.  
  5. Remove the fuel tank mounting straps, then carefully remove the fuel tank from the vehicle.
  6.  



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Fig. Fig. 7: The fuel tank is secured with 2 mounting straps-1998 shown, other years similar

To install:
  1. Position the fuel tank onto the transmission jack.
  2.  
  3. Raise the tank into position. Connect the fuel filler tube tank inlet nipple.
  4.  
  5. Tighten the fuel tank strap nuts to 17 ft. lbs. (23 Nm). Remove the transmission jack. Make sure the straps are not twisted or bent.
  6.  
  7. Attach the quick-connect fuel tubes to the pump module and chassis fuel tube.
  8.  
  9. Connect the fuel vapor tube to the tee, then to the EVAP canister tube.
  10.  
  11. Attach the fuel pump module electrical connector.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Fill the fuel tank, install the filler cap, then connect the negative battery cable.
  16.  

 
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