pretty easy job, there are 2 straps that hold the tank to the trunk floor.
on top of the tank is a rubber hose connected to the fuel vapor system.
buy the premium replacement tank from OMS or another vendor, that has the galvanized finish so it won't rust.
drain the old tank.
pull the wire connector off the fuel sender on the drivers side.
pop the seal ring on the fuel sender and inspect the sender for damage or rust. if it looks good you can reuse it otherwise you can get a stainless steel replacement.
use a car jack under the tank support the tank.
unscrew the gap cap, pop the 5-6 hex head screws that hold the filler neck to the taillight panel.
pop the 4 Phillips head screws on the tank floor that hold the rubber seal to the trunk floor.
wiggle the neck make sure it is free, pull it out. the rubber floor seal should come out and there will be a cork ring gasket on the back side of the tail panel.
pop the 2 bolts just behind the rear valance under the truck floor, that will release the 2 straps that hold the tank.
drop the tank slow.
get enough clearance so you can pop the rubber hose off the top of the tank or cut it with a hose cutter.
drop the tank.
once the tank is clear pop the top ring on the tank and pull out the fuel vapor cap they DO NOT MAKE THESE you need to save it.
with the new tank, you should get 2 o rings. there should be 2 retainer rings as well.
sometimes they sell complete kits but you want to add.
1) tailpanel cork gasket.
2) rubber filler neck seal to trunk floor.
3) some new fuel line hose.
clean out the top vapor cap usually it is full of garbage and varnish.
with the tank out inspect the vapor return hard line under the car, if it is full of fuel varnish you will want to replace it. that will not be easy with the trans and engine in the car but it can be done.
4) optional vapor return line replacement
5) filler neck gasket dougnut
you can use some motor oil to lube the orings, but reinstall the top vapor cap on the new tank.
then install a length of replacement rubber hose on it with clamps so when you make the final connection to the vapor hard line it willbe easy.
Install the new filler neck gasket that goes into the tank lip, now you can accidentally push that gasket into the tank and it will fall in,, another reason not to install the sender yet,,, so you can reach into the tank and grab the gasket if you have an accident
you can install the fuel sender last if you wish to prevent damage during install.
(also you can replace the sock on the sender if you wish)
jack the tank into place, now here is the issue.
the straps molded themselves to fit the old tank the new tank is slightly differently shaped, you have to kind of rebend the straps slightly to fit the tank and it will be a big Pain in the butt but they will fit once you get the nut or bolt started on the straps then you can torque everything down.
put some oil on the filler neck gasket and then start to push that filler neck back in, make sure you preinstall the rubber floor gasket on the filler neck just push it up out of the way as you install it into the tank.
remember to put the cork gasket back between the filler neck and the tail panel, reinstall the screws.
now with the tank and filler neck and the truck seals all back together install the fuel sender.
connect all hoses.
Fill tank with 5 gallons of gas. let sit,,,, inspect for leaks.
the sender can leak from a couple of places so the replacements are known to leak from the electrical connector rubber seal. if it leaks you need to drain the tank, and pop the sender and replace it or figure out why it is leaking.
(i had to replace my replacement sender 2 times before i got a good one)
now with no leaks and 5 gallons of gas get into the car, put the key and turn to accesories or run,,, not start yet.
look at the fuel gauge it should read 1/4 full approx.. if not you have to pull the sender out and start bending the float draining and refilling the tank... over and over and opening the sender oring seal over and over.... yup it sucks i gave up. my fuel gauge is only accurate to within 1/4 of a tank. when i get to half on the gauge i know i'm about 1/4" from empty,,, yippy
..
once you have had enough of that,, start the engine inspect for leaks,,, no leaks go for a spin fill up with new gas.
for the next few days give everything a inspection to make sure nothing is weeping or leaking, yhea it can happen, everything is made in china now.
