2004 Chrysler PT Cruiser Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Installation

  1. Position fuel tank on transmission jack.
  2. Raise fuel tank into position.
  3. Connect vacuum line to LDP.
  4. Install EVAP line and recirculation line.
  5. Connect electrical connector and lock the connector.
  6. Connect the fuel line. Refer to QUICK CONNECT FITTING .
  7. Connect fuel fill tube to tank inlet. Tighten hose clamp to 3.5 N.m (31 in. lbs.) torque.
  8. Position fuel tank straps. Tighten fuel tank strap bolts to 23 N.m (250 in. lbs.) torque. Remove transmission jack. Ensure straps are not twisted or bent.
  9. Lower vehicle.
  10. Fill fuel tank, install filler cap.
  11. Install the negative battery cable.
  12. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
  13. Use the DRBIII® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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