Rajan Wilcox
Dropping the fuel tank on a PT Cruiser is not an easy task. The fuel pump is located inside the fuel tank, and there is no access panel inside the car to reach it. The only way to access the pump is by dropping the tank. Before dropping the tank, it is important to siphon out enough gas to reduce the weight of the tank. This can be done by removing the filler hose or using a siphon pump. Once the tank is lowered, the fuel pump supply and return hoses, EVAP system hoses, and electrical connections must be disconnected before removing the pump. It is also important to check for excessive corrosion on the fuel tank straps and fasteners and replace them if necessary.
Characteristics and Values Table for Dropping Fuel Tank on PT Cruiser
| Characteristics | Values |
|---|---|
| Easy way to empty gas from tank | No easy way to empty the tank. The fuel pump has to be removed to empty the tank |
| Access to fuel pump | No access panel on the inside of the PT Cruiser to access the pump. The tank has to be dropped to access the pump |
| Fuel pump failure symptoms | Car won't start or unexpectedly stalls and won't restart |
| Fuel pump replacement | A new fuel pump should be installed along with a new fuel filter |
| Fuel tank leak | Disconnecting the vapor pipe near the fuel tank and shooting air into the pipe can release the valve |
| Fuel tank leak | A new fuel tank may be required if the valve is stuck |
| Fuel tank leak | Removing the gas cap allows airflow to release the flapper that is stuck closed |
| Fuel tank drop | Siphoning out gas can help to drop the tank with less weight |
| Fuel tank drop | A floor jack with a wood board can be used to lower the tank enough to disconnect lines |
| Fuel tank drop precautions | Check for excessive corrosion and replace tank straps and fasteners as needed |
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What You'll Learn
Removing the fuel pump assembly
To remove the fuel pump assembly, you will first need to siphon out some fuel to reduce the weight of the tank. You can do this by removing the gas cap to allow airflow and release the flapper that is stuck closed. Alternatively, you can use a siphon pump to remove some of the fuel. Once the tank is lighter, you can start to lower it from the vehicle. Place a floor jack with a wooden board underneath the tank to lower it enough to disconnect the lines. Be very careful with the fuel lines, and be aware that exposed fuel and fumes are extremely flammable. Use a well-ventilated area and keep a Class B fire extinguisher on hand.
Once the tank is lowered, you will need to remove the fuel pump supply and return hoses, as well as the EVAP system hoses and electrical connections to the pump. If there is no access panel in your PT Cruiser, you will then need to drain the remaining fuel from the tank. After the fuel is drained, you can remove the fuel pump assembly. It is recommended to replace the fuel filter at this point as well, as running the tank with diesel will contaminate the filter.
After removing the fuel pump assembly, you will need to clean out the tank. You should also check the fuel tank straps and fasteners for excessive corrosion and replace them if necessary. Finally, install the new fuel pump assembly and fuel filter, and fill the tank with fuel. It is recommended to keep the gas tank at least a quarter full to maximize the life of the new fuel pump.
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Emptying the gas tank
To empty the gas tank of a PT Cruiser, you will need to drop the tank and remove the pump assembly. Here are the steps you can follow:
- Siphon out some gas to reduce the weight of the tank: Use a siphon pump or a smaller tube to remove some gasoline from the tank. This will make it easier to drop the tank as it will be lighter. Be extremely cautious when handling gasoline, as it is highly flammable. Store the siphoned gasoline in approved closed containers in a well-ventilated area, and keep a fire extinguisher nearby.
- Lower the tank: Place a floor jack with a wooden board to lower the tank enough to disconnect the lines. You may need to maneuver the tank to work it past the exhaust. Be careful not to nick any hoses or wires during this process.
- Remove the pump assembly: With the tank lowered, you can now remove the pump assembly. This will involve disconnecting the fuel pump supply and return hoses, EVAP system hoses, and electrical connections to the pump.
- Dump out the remaining diesel: Once the pump assembly is removed, you can now dump out the remaining diesel from the tank. Be sure to do this in a safe and environmentally friendly manner.
- Clean the tank: After emptying the tank, it is important to clean it thoroughly before installing a new pump.
It is important to note that you should not attempt this task if you are uncomfortable or unfamiliar with automotive repairs. Always prioritize safety and consult a qualified mechanic if you have any doubts or concerns.
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Replacing the fuel pump
To replace the fuel pump on a PT Cruiser, you must first empty the fuel tank. It is not recommended to turn on the engine and let the fuel pump run dry as this will destroy the pump in the process, both by diesel contamination and overheating. There is also no access panel inside the PT Cruiser to access the pump. Therefore, the best way to empty the tank is to siphon the gas out or disconnect the filler hose.
Once the tank is empty, you can start to drop it. Place a floor jack with a wooden board to lower the tank enough to disconnect the lines. Be careful not to nick the hoses or wires. The exhaust is suspended with rubber hangers, so a shot of silicone spray on the hooks and a pry bar can be used to release them and push the exhaust system out of the way.
With the tank dropped, you can now access the fuel pump for replacement. It is important to note that the fuel and its fumes are extremely flammable, so use a well-ventilated area with no nearby ignition sources and keep a Class B fire extinguisher on hand.
Finally, with the new fuel pump installed, you can raise the tank back into position and reconnect the lines.
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Checking for fuel leaks
Before dropping the fuel tank on a PT Cruiser, it is important to check for any fuel leaks and address them to prevent any safety hazards. Here are some detailed steps and instructions for checking and dealing with fuel leaks:
Identifying Fuel Leaks:
- One common issue with PT Cruisers is a fuel leak around the fuel tank, specifically where the filler hose is connected. This can be due to a loose hose clamp or a small hole in one of the hoses.
- Another potential leak point is the evaporative system hoses. Check for a stuck-closed fuel control valve or a restriction in these hoses, which can cause the \"hard fill\" condition.
- If there is an overflow of gas when filling up the tank, it could be due to a stuck flapper door where the fill neck attaches to the fuel tank, allowing fuel to come up the fill neck.
- A valve inside the tank, which is supposed to let air through but not fuel, can also get stuck and cause issues. This may require a new fuel tank to fix.
Temporary Solutions:
- Removing the gas cap when the tank is low can help release a flapper that is stuck closed, allowing you to fill up the tank.
- Disconnecting the vapor pipe near the fuel tank and shooting air into the pipe can release the stuck valve, but this may only be a temporary solution.
Permanent Solutions:
- For more permanent solutions, it is recommended to consult a professional mechanic or a Chrysler dealer, especially if you are uncomfortable with performing these tasks yourself.
- Replacing the entire filler assembly down to the tank may be necessary.
- In some cases, a new fuel tank and fuel pump may be required to fix the issue, especially if there is a valve problem inside the tank.
- If you have run diesel through the fuel pump, it will likely need to be replaced, and the tank will need to be cleaned out properly.
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Disconnecting the filler hose
Before starting, it is essential to siphon or drain some fuel from the tank to reduce its weight. This step is crucial for safety and ease of handling. Place a floor jack with a wooden board underneath the tank to support it during the process. Ensure you have approved fuel containers ready to collect the drained fuel, and always keep a fire extinguisher nearby as a safety precaution.
To begin disconnecting the filler hose, locate it where it connects to the fuel tank. Carefully remove the hose, being mindful of any residual fuel that may spill out. It is important to note that some PT Cruiser models may have a tank drain near the hose, allowing for easier fuel drainage before disconnecting the hose.
Once the filler hose is disconnected, you will have access to the fuel pump assembly. It is important to be cautious when moving the tank around, as some fuel may still be present, and you want to avoid any spills or leaks. The next steps would involve removing the fuel pump supply and return hoses, EVAP system hoses, and electrical connections to the pump.
After disconnecting the filler hose and accessing the fuel pump, it is crucial to clean the tank thoroughly before installing a new pump. Failing to do so can lead to issues down the line. Additionally, always refer to a mechanic or a professional for guidance if you are unsure about any steps in the process.
Overall, disconnecting the filler hose on a PT Cruiser is a delicate procedure that requires careful handling of fuel and attention to safety. By following these steps, you can successfully access the fuel pump and proceed with further maintenance or repairs.
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Frequently asked questions
There is no easy way to do this. You need to first siphon out enough gas to drop the tank with less weight. Then, lower the tank and remove the pump assembly to dump out the remaining diesel.
After dropping the tank, you need to clean it out. You will also need to replace the pump as running diesel through it will cause it to fail within 1000 miles.
Exposed fuel and fumes are extremely flammable. Ensure you are working in a well-ventilated area with no nearby ignition sources. Keep a Class B fire extinguisher on hand.
