Pulling an old fuel tank down and replacing it will take some time to do, but in the end you will learn why repair shops charge so much for doing fuel tank jobs. The gas tank is fairly easy to get to, as it is located in the back of the car. However, it is rather bulky, so handling it can be a little awkward. Your room is very limited, as you have to do the entire job upside down. You will be on your back the entire time as you remove and install the tank.
Drain the fuel tank. The drain plug should be located on the bottom of the tank. You will need a pair of pliers to loosen the drain plug.
Jack the car up to give you extra room to work in.
Locate the two straps holding the tank in place. They will run the length of the car.
Loosen the four bolts on the end of the straps with a ratchet. Do not remove the bolts until the tank is supported.
Place a jack under the tank. This will support the tank as you remove the straps.
Remove the four bolts. The tank will fall as you remove the last bolt. Support the tank on the jack. This will keep the tank from ripping the fuel lines.
Remove the fuel inlet hose on the back of the tank. Use a screwdriver to undo the hose clamp. The hose will work itself loose as you pull it off the tank.
Unsnap the hose lines that are running out of the gas tank. The hose lines are held on by a quick-release fitting. A flathead screwdriver should give you the leverage to disconnect the hose lines.
Unscrew the assembly located at the top of the tank. The assembly will be tight, so use a screwdriver as a chisel and hammer it loose. The assembly should come out.
Note that there is an O-ring located on the threads where you removed the assembly. You will need a fresh O-ring on the new tank.
Place the O-ring on the threads. Be sure the O-ring is brand new.
Screw the assembly to the top of the fuel tank. Torque the cap down by hammering the chisel to turn the assembly to a snug position.
Place the new tank on the jack under the car. This will keep the jack supported so you can attach the wires and hoses.
Install the inlet hose on the back of the tank. Be sure to tighten the hose clamp.
Snap the fuel lines and wires back to the connections they were removed from earlier. This is easier when you have the tank supported on the jack.
Hold the fuel tank in position as you place one of the straps holding it up. Make sure your bolts are in reach, since your movement will be limited as you are holding the tank up.
Start the bolts in the strap. Do not tighten the bolts; you will need the extra leverage for installing all the other bolts.
Start the remaining bolts. Tighten all the bolts when all four are started in their respective holes. Ensure that all the bolts are snug.
Pour gasoline in the new tank. You will need at least three gallons to ensure that the fuel pump picks up the fuel.
Crank the car. Turn the key over till the car starts. The car may not start on the first try.
