Replacing Pt Cruiser Fuel Tank: Step-By-Step Guide

Replacing the fuel tank on a Chrysler PT Cruiser is a complex task that requires a good understanding of car mechanics. The fuel tank is responsible for storing engine fuel and is typically mounted to the bottom rear of most vehicles. The average cost for a Chrysler PT Cruiser Fuel Tank Replacement is between $1,002 and $1,034, with labor costs estimated between $123 and $155, and parts priced around $879.

Before attempting to replace the fuel tank, it is important to diagnose the issue. One common problem is a restriction in the evaporative system hoses, which can cause the gas pump to stop working properly. Another issue could be a stuck closed fuel control valve, which regulates the flow of fuel. If the fuel tank needs to be replaced, it is recommended to get assistance due to the size and weight of the tank.

It is important to note that working with fuel can be dangerous, so proper precautions should be taken to avoid fire hazards, and the battery should always be disconnected.

Removing the fuel tank

To remove the fuel tank from a PT Cruiser, first disconnect the battery to ensure safety precautions against fire hazards are met.

Next, you will need to empty the fuel tank. You can do this by siphoning the fuel out of the tank and into an approved fuel container. Be aware that exposed fuel and fumes are extremely flammable, so ensure you are in a well-ventilated area with no nearby ignition sources. Keep a Class B fire extinguisher on hand.

Once the tank is empty, you will need to disconnect the fuel pump supply and return hoses, as well as the EVAP system hoses and electrical connections to the pump. You may need to lower the tank carefully to access these lines. If you are struggling to access the lines, you can try to carefully manoeuvre the tank past the exhaust by releasing the rubber hangers with a shot of silicone spray and a pry bar.

Now you can fully remove the tank. The tank is mounted to the bottom rear of most vehicles. You may need to carefully cut a hole in the floorboard to access the tank, but this is not recommended by many people. Alternatively, you can lower the tank and remove it from the vehicle.

Remember, fuel tanks are large, cumbersome, and can be extremely heavy, so it is recommended to have an assistant help you with this process.

Disconnecting the fuel pump

Before disconnecting the fuel pump, you must first drain the fuel tank. Do not attempt to empty the tank by turning the engine over, as this will destroy the fuel pump in the process. Instead, use an approved method to siphon the fuel out of the tank and into safe storage containers. Be aware that exposed fuel and fumes are extremely flammable, so take the necessary precautions and work in a well-ventilated area.

Once the tank is empty, you can begin the process of disconnecting the fuel pump. If your vehicle has an access panel above the tank in the passenger compartment, you can remove the pump through this opening. If not, you will need to lower the fuel tank from the vehicle to gain access to the pump. Place a floor jack with a wooden board underneath the tank to support it during this process.

When lowering the tank, be careful not to nick any hoses or wires. Maneuver the tank carefully to avoid the exhaust system, and use a pry bar to release the rubber hangers if necessary. If your tank has a capped drain port, you can siphon fuel from there.

With the tank now accessible, the next step is to remove the fuel pump supply and return hoses, as well as the EVAP system hoses, and electrical connections to the pump. Take pictures or make notes of the routing and connections to ensure proper reassembly.

Finally, remove the fuel pump assembly from the tank. Be sure to clean the tank thoroughly before installing a new pump.

Draining the fuel tank

To drain the fuel tank of a PT Cruiser, you will need to first remove the fuel from the tank. This can be done by siphoning the fuel out using a siphon tube and hand pump or by removing the filler neck hose where it connects to the fuel tank. Be extremely cautious when handling fuel, as it is highly flammable. Work in a well-ventilated area, keep a fire extinguisher on hand, and store the fuel in approved closed containers.

Once the fuel has been removed, you can begin the process of dropping the tank. Place a floor jack with a wood board underneath the tank to lower it carefully. Be cautious when handling the tank, as the plastic can be brittle and may crack if dropped or mishandled.

With the tank lowered, you will need to disconnect the fuel lines, EVAP system hoses, and electrical connections to the pump. Take note of the routing of the hoses and wires, as you will need to reconnect them later.

At this point, you should be able to access the fuel pump and begin the process of replacing it. Remember to install a new fuel filter if the old one is dirty or clogged. Also, check the fuel tank straps and fasteners for corrosion and replace them if necessary.

Finally, raise the tank back into position and reattach the hoses and electrical connections. Add fuel to the tank and start the engine to test for leaks.

Installing the new fuel pump

To install the new fuel pump, you will need to follow these steps:

• Test the new fuel pump to ensure it is functioning.
• Gain access to the old fuel pump by removing it from the tank through an access panel above the tank in the passenger compartment. If no access panel exists, drain the fuel from the tank and then lower the tank from the vehicle.
• Disconnect the fuel pump supply and return hoses, EVAP system hoses, and electrical connections to the pump.
• Attach any reusable brackets and pick-up screens to the new pump.
• Install the new fuel pump.
• Re-establish all hoses and electrical connections.
• Refill the fuel tank and run the engine to test for leaks.

It is important to note that you should replace the fuel filter when installing a new fuel pump, as well as check the fuel tank straps and fasteners for corrosion and replace them if necessary. Additionally, it is recommended to keep the gas tank at least a quarter full to maximize the life of the new fuel pump.

Reattaching the fuel tank

First, you will need to ensure the fuel tank is empty. This can be done by siphoning the fuel out or draining it through the tank's drain port. Once the tank is empty, you can begin to reattach it.

If you have access to an assistant, carefully lower the tank back into place, ensuring it is correctly aligned. If you are working alone, you may need to use a jack to support the tank while you reattach the fuel lines, EVAP system hoses, and electrical connections. Be extremely careful not to kink or damage any of the hoses or lines.

Once the tank is in place, carefully reattach all the hoses and electrical connections. Ensure that all connections are secure and tight to avoid any leaks.

After everything is reconnected, fill the tank with fuel and check for leaks. Turn on the engine and observe for any signs of leakage. If no leaks are detected, your fuel tank replacement is complete.

It is important to note that working with fuel can be dangerous, and proper precautions must be taken to avoid injury or damage to the vehicle. Always disconnect the battery and take the necessary steps to prevent fire hazards.

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