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Here's my $0.02 worth:
1. Siphon out as much fuel as possible.
2. Unhook the hoses underneath and the return hose on top.
Be prepared to catch fuel in a pan underneath. Unhook the
wire to the fuel sender (fuel level sensor).
3. Disassemble the fuel filler neck hardware (I don't recall all
of the details for doing this, but it is straight-forward. Just
take enough jpegs and label things so you know how to
reassemble.
4. The tank is held in by screws around the perimeter. These
are unscrewed from the top side (inside the trunk).
5. Lift the tank out. It helps to have someone underneath
pushing the tank up while you lift from above, but it can be
done alone. If your car is anything like mine, the tank will
get hung up between the wheel housing wall and the sheet
metal surrounding the tail lamp. You will have to jocky the
tank around to find the path of least resistance.
6. Remove the fuel sender from the tank. Take note of the
installation orientation.
7. Your car might have an internal fuel pump to remove. My '77 didn't.
8. I used the POR-15 tank cleaning/sealing kit. Eastwood makes
a kit as well. The POR-15 kit works very, very well but you
need to follow the instructions to the letter.
Hope this helps! Overall, it is pretty easy to do.
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Bill ---- 1977 Alfa Romeo 4C2000 ---- 2000 Aprilia Mille
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