Replacing the fuel tank gasket without dropping the tank
The fuel tank gasket, properly named Fuel Filler Tube Grommet can be replaced WITHOUT dropping the tank, just follow the instructions below.
Although you are not dropping the tank, it may be wise to wait to do this job until you have 1/4 or less of fuel in the tank. Also, before you start, you may want to wash the area around to prevent dirt from getting in the tank and to make things less messy. Just donít spray directly into the damaged grommet or water might get in the tank.
Parts you need
Parts you may consider getting while you are doing this
- Fuel hose for the overflow
- Replacement hose clamps
- Fuel Filter (while you have the car jacked up, it may be a good idea to replace the filter.
- Jack up the rear right end of the vehicle. Remember to use a jack stand for safety.
- Remove the wheel.
- Remove the screw that secures the filler tube bracket (purpose of this bracket unknown but observe the position, you could reinstall it backwards)
- Loosen the hose clamps and remove the overflow return hose. If it stains your hands, replace it, as it has worn out.
- (Optional) If the gas fumes make you dizzy, tape the open holes of the tank with tape to keep the fumes in).
- Remove the trunk latch plastic cover and the rear upholstery mold from the trunk. If necessary, remove the farthest plastic pushpin from the front upholstery mold so that you can move the right side upholstery mold out of the way.
- Remove the gas cap (observe that the gas cap cable attaches to the bottom screw. Installing it in any two of the top will make the gas cap be in the way everytime you refuel).
- Remove the 3 screws that hold the filler tube dust boot (8mm), the 3 screws that hold the filler tube to the plastic fuel filler housing (10mm), and the 4 screws that hold the plastic fuel filler housing to the fender.
- Work the filler tube out of the tank by pulling and turning. You will need to move the filler tube housing out of the way in order to bring up the filler tube. Two people, one pulling close to the tank and one guiding the tube from inside the trunk make the job a snap. The tube comes out through the trunk.
- (Optional) If your trunk shows excessive dirt on the filler-tube area, it may be due to the looseness of the dust boot at the choke part of the filler tube. You may want to install a hose clamp on the underside of the boot. Do no tighten it until you finish the installation.
- Remove the damaged grommet from the tank and reinstall the new one. Apply a little oil to the grommet before you reinsert the filler tube.
- Remember to insert the bracket in the filler tube observing position, before you proceed to reinsert the filler tube in the tank.
- Work the tube into the tank.
- Reinstall all screws but do not tighten any, including the hose clamps to the overflow hose until you have finished installing all of them.
The rest of the installation is the reverse of removal.