Katerina Swanson
Removing the fuel tank from a PT Cruiser can be a challenging task. Several owners have reported issues with filling the gas tank, often due to a stuck valve inside the tank that prevents vapours from escaping during refuelling. While some temporary solutions involve disconnecting the vapor pipe and shooting air into it, or using a siphon tube to force a siphon beyond the rollover valve, the ultimate solution may require replacing the entire fuel tank. This process can be cumbersome, as accessing the fuel pump involves dropping the tank, which is challenging with a full tank of gas. Thus, it is crucial to first remove enough fuel from the tank before attempting to drop it.
Characteristics and Values Table for Removing Fuel Tank from PT Cruiser
| Characteristics | Values |
|---|---|
| Difficulty | Not easy |
| Fuel Tank Replacement | Common issue |
| Cause | Stuck valve, float ball stuck in place |
| Temporary Fix | Disconnecting vapor pipe, shooting air into the pipe |
| Permanent Fix | Replacing the fuel tank |
| Fuel Removal | Siphoning, draining, disconnecting fuel pump assembly |
| Fuel Tank Access | Dropping the tank, cutting an access hole |
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What You'll Learn
Emptying the gas tank
Firstly, it is essential to understand that attempting to empty the gas tank by turning on the engine and running the fuel pump is not recommended. This method can cause significant damage to the fuel pump due to diesel contamination and overheating. Therefore, it is best to avoid this approach unless you intend to replace the fuel pump altogether.
One suggested method to empty the gas tank is to use a siphoning technique. This involves forcing a siphon tube beyond the rollover valve, allowing you to use a traditional siphon method to remove the fuel. It is important to cut a taper on smaller plastic tubing for this technique to be effective. You can refer to a YouTube video at the link https://www.youtube.com/watch?v=2mGeb9s6yFE for a visual demonstration of this method.
Another approach is to disconnect the vapor pipe near the fuel tank and blow some air into it to release the valve. This method can be effective, but there is a chance that the valve may get stuck again. To mitigate this, you can try lubricating the valve with WD40 before blowing air into the pipe.
If you need to drop the tank to access the fuel pump assembly, it is crucial first to empty the tank to a manageable weight. A full tank of gas can weigh approximately 16 gallons, making it challenging to handle. By siphoning out enough gas, you can reduce the weight and make it easier to drop the tank safely.
Additionally, it is worth noting that there is no easy access panel inside the PT Cruiser to access the fuel pump directly. Therefore, dropping the tank or cutting an access hole may be necessary, but it is generally discouraged by many people.
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Disconnecting the vapor pipe
First, locate the vapor pipe near the fuel tank. This pipe is responsible for circulating vapors and gases released during fuelling. It is usually found at the rear of the car, connected to the fuel tank.
Before disconnecting any components, ensure the vehicle is safely parked and secure, with no potential hazards nearby. Wear appropriate protective gear, such as gloves and eye protection, to safeguard against any fuel or debris.
Once you've located the vapor pipe, identify the quick disconnect fitting. This is a specialized coupling designed for easy and rapid connection and disconnection. It is typically located near the vapor pipe and the fuel tank. Using the appropriate tools, carefully detach the vapor pipe from the quick disconnect fitting. This step may require some force, but be gentle to avoid damaging any surrounding components.
After successfully disconnecting the vapor pipe, you may need to blow some air or a small amount of lubricating substance, such as WD40, into the pipe to release the stuck valve. This step can help dislodge any blockages and improve the function of the valve.
Finally, if you are unable to release the valve or if it becomes stuck again shortly after, it may be necessary to replace the entire fuel tank. Sometimes, the valves are integrated into the tank, and individual valve replacements might not be available. Consult a professional mechanic or a trusted repair shop for further advice if needed.
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Removing the fuel pump
To remove the fuel pump from your PT Cruiser, you will first need to empty the gas tank. Do not attempt to empty the tank by turning the engine over and letting the fuel pump do the work, as this will destroy the fuel pump in the process, both by diesel contamination and overheating.
There is no easy way to empty the gas tank of a PT Cruiser. One method is to disconnect the vapor pipe near the fuel tank and blow some air into it to release the valve. You can also try lubricating the valve with WD40 to avoid sticking. Another method is to siphon the gas out of the tank using a siphon pump.
Once the tank is empty, you will need to drop the tank to access the fuel pump assembly. There is no access panel on the inside of the PT Cruiser to access the pump, so you will need to remove the tank completely. Be careful not to nick any hoses or wires when dropping the tank.
With the tank removed, you can now access the fuel pump for replacement. It is recommended to also replace the fuel filter at the same time, as it is part of the pump assembly.
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Replacing the fuel tank
To replace the fuel tank of a PT Cruiser, you must first empty the gas tank. There is no easy way to do this, and it is not recommended to turn on the engine to empty the tank, as this will destroy the fuel pump. Instead, you can siphon the gas out of the tank using a siphon tube and a pump, or by disconnecting the vapor pipe near the fuel tank and blowing air into it. Once the tank is empty, you can remove it by dropping it or cutting an access hole without dropping the tank. Be careful not to nick any hoses or wires. After removing the old fuel tank, you can install the new one by following the manufacturer's instructions. Ensure that all connections are secure and that there are no leaks before filling the new tank with gas.
If you are replacing the fuel tank due to a problem with the fuel pump, it is important to note that this is an expensive repair, as the tank must be removed to access the pump. You may need to replace the pump if it has been contaminated with diesel or if it has overheated.
In some cases, it may be possible to fix the issue without replacing the entire fuel tank. For example, if the problem is caused by a stuck valve, you may be able to release it by disconnecting the vapor pipe and blowing air into it or by using a lubricant such as WD40. However, if the valves are stuck and cannot be released, or if there is a problem with the tank itself, replacement may be the only option.
When replacing the fuel tank, it is important to follow all safety precautions, including wearing protective gear and ensuring proper ventilation to avoid inhaling fumes. It is also crucial to dispose of the old fuel tank and any leftover fuel properly, following local regulations and guidelines.
It is recommended to refer to the PT Cruiser service manual or seek advice from a qualified mechanic if you are unsure about any part of the process or if you encounter any problems during the replacement.
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Replacing the control valve
The control valve in a PT Cruiser's fuel tank is responsible for regulating the flow of fuel vapors to the EVAP canister during refueling and vehicle operation. It is an essential component of the evaporative emissions control system. When replacing the control valve, it is important to follow these steps:
First, locate the control valve. In most PT Cruisers, it is fixed into the top right corner of the fuel tank. It is usually a small, plastic valve connected to the EVAP canister. Before beginning any work, it is crucial to ensure your safety. Wear protective gear, including gloves and eye protection, and make sure you are in a well-ventilated area. Fuel and its fumes are highly flammable, so keep a fire extinguisher nearby.
Next, disconnect the control valve from the EVAP canister and any other attached components. This may involve unscrewing or detaching hoses and wires. Be careful not to damage any surrounding parts or connections. Once the old control valve is removed, clean the area thoroughly to avoid any dirt or debris entering the fuel system. Inspect the area for any signs of damage or corrosion, and address them accordingly.
Now, you can install the new control valve. Ensure it is an exact replacement and securely attach it to the EVAP canister and any other necessary connections. Refer to a professional mechanic or the manufacturer's instructions for specific installation steps, as they may vary depending on your vehicle's make and model.
Finally, carefully reattach any hoses, wires, or components that were previously disconnected. Double-check that all connections are secure and properly attached. Once you have completed the replacement, it is important to test the system. Start the vehicle and observe for any unusual noises or smells. Ensure that the fuel system is functioning correctly, and there are no leaks.
By following these steps, you can effectively replace the control valve in your PT Cruiser's fuel tank. This process requires attention to detail and a good understanding of automotive systems. If you are unsure or uncomfortable with any part of the process, it is always best to consult a professional mechanic to ensure a safe and proper repair.
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Frequently asked questions
There is no easy way to empty the fuel tank of a PT Cruiser. You need to drop the tank to remove the pump assembly and dump the fuel.
The fuel pump is inside the fuel tank of a PT Cruiser, so the tank must be removed to access it. There is a YouTube video that shows how to cut an access without dropping the tank.
The fuel tank capacity of a PT Cruiser is about 16 gallons.
Some common issues with the fuel tank of a PT Cruiser include a stuck float ball and a stuck valve inside the tank.
