Who has been through this fun?

New gas tank will be here and know I need to remove the rear bumper.

Is there a few pages of the FSM, that I still do not own, that detail the process?

Car is an 85. Tank is trash and going back with a baffled, sumped, and external pump setup.

Thanks for the help.

I had started the job on my '91 but was not able to finish it, mainly because I have no garage and have to work in my driveway :-) My mechanic finished the job and said it was quite a bit of work, including having to drop the rear half of the exhaust system. I think I could have finished the job had I been able to work in a garage with some more time (I ran out of patience LOL)

Quote:

Do you have the Haynes repair manual? If not, I have it and can take a look when I get home for you.

REMOVAL

1.Remove battery ground cable.
2.Drain fuel tank.
3.Remove fuel tank filler door.
4.Remove fuel tank filler neck housing and drain hose.
5.Disconnect fuel feed hose, fuel return hose, vapor hose and electrical connector from fuel meter and pump assembly.
6.Remove license plate to gain access for fascia to impact bar bolts.
7.Remove 2 carriage bolts securing fascia to impact bar.
8.Raise vehicle on hoist.
9.Remove spare tire and tire carrier.
10.Disconnect oxygen sensor electrical connector.
11.Remove exhaust system as a complete unit by disconnecting from front crossover pipe at exhaust manifold. Refer to See: Engine, Cooling and Exhaust\Exhaust System\Diagrams
12.Remove both inner fender braces.
13.Remove both rear inner fender panels.
14.Disconnect antenna ground strap.
15.Remove bolt securing fuel vapor pipe to left hand fuel tank strap.
16.Disconnect fuel tank cables from rear right and left hand stabilizer shaft brackets.
17.Remove all rear lamps (side marker, tail, backup. license plate and spare tire.
18.Remove 4 screws securing bottom edge of fascia to energy absorber pad.
19.Remove 3 nuts securing each side of fascia to horizontal body retainer.
20.Remove nuts from right and left vertical retainers securing fascia to body.
21.Remove 4 frame extension bolts (2 each side).
22.Loosen. but do not remove 4 remaining frame extension bolts.
23.With the aid of an assistant. remove remaining frame extension bolts and pull fuel tank and frame assembly rearward pushing cover outward. Tilt assembly down to remove and clear cover.
24.Remove tank straps and remove tank. If fuel tank is being replaced transfer cables. fuel meter and pump. and fuel vapor connector to new tank

PM me your email, I can cut/paste the pictures as well.

If you're pulling the bumper I'd put in a tube frame instead. Save a few pounds. Melrose used to sell one, but I don't know if they do much C4 stuff these days.

INSTALLATION

1.Position tank on frame extension and secure to tank supports with straps.
2.With the aid of an assistant, install tank and frame assembly in vehicle and secure with bolts.
3.Install nuts on right and left vertical retainers.
4.Install 3 nuts securing each side of fascia to horizontal body retainer.
5.Install screws securing bottom edge of fascia energy absorber pad.
6.Install all rear lamps and spare tire lamp.
7.Install fuel tank cable to stabilizer shaft brackets.
8.Install bolt securing fuel vapor pipe to left hand fuel tank strap.
9.Connect antenna ground strap.
10.Install both rear inner fender panels.
11.Install both inner fender braces.
12.Install exhaust system.
13.Connect oxygen sensor electrical connector.
14.Install spare tire and carrier.
15.Lower vehicle.
16.Install bolts securing fascia to impact bar.
17.Install license plate.
18.Connect fuel feed hose, fuel return hoses, vapor hose and fuel meter electrical connector.
19.Install fuel tank filler neck housing and drain hose.
20.Install fuel tank filler door.
21.Connect battery ground cable.
22.Add fuel to tank.

How would a tube frame weight less? I will look into it either way.

I found the FSM scanned online for free.

Thanks everyone