Fuel Tank Strap

Remove and replace the fuel tank mounting straps on a 1992 Dodge Viper, including fuel system depressurization, tank lowering, and strap installation with proper torque specifications.

Warnings

Tools required

Parts

• Fuel tank strap (driver side) × 1 — Mopar 4593682 or equivalent
• Fuel tank strap (passenger side) × 1 — Mopar 4593683 or equivalent
• Fuel line O-rings × 4 — Use OEM specification
• Strap mounting bolts × 4 — Replace if corroded

Preparation

1. Park vehicle on level ground outdoors or in a well-ventilated garage with no ignition sources nearby
2. Ensure fuel tank is less than 1/4 full if possible. If tank is fuller, siphon fuel into approved containers using a manual siphon pump
3. Position Class B fire extinguisher within immediate reach
4. Disconnect negative battery cable and isolate it away from the battery terminal
5. Allow vehicle to sit for at least 30 minutes after last operation to cool exhaust system
6. Chock front wheels securely
7. Raise rear of vehicle using floor jack and support on jack stands rated for at least 4 tons, positioned at manufacturer-specified jacking points on the frame rails
8. Ensure vehicle is stable and will not shift during work

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pressure test port on the fuel rail. Remove the protective cap from the Schrader valve. Attach a fuel pressure gauge with a bleed valve to the test port. Open the bleed valve slowly and drain fuel into an approved container until pressure gauge reads zero. Close bleed valve and remove gauge. Reinstall protective cap on test port.
   ⚠️Fuel will spray from the test port. Keep face and ignition sources away. Have drip pan positioned to catch fuel.
2. 2

   Access fuel tank area
   Position yourself under the rear of the vehicle. Identify the fuel tank located at the rear of the vehicle in the vicinity of the rear axle. Locate the fuel filler neck, vent lines, fuel supply and return lines, and electrical connector for the fuel pump module on top of the tank.
   ⚠Inspect the exhaust system and ensure all components are cool before proceeding.
3. 3

   Disconnect fuel filler neck
   Locate the fuel filler neck hose connected to the tank inlet on the driver side of the tank. Loosen the hose clamp securing the filler neck to the tank using a socket or screwdriver. Carefully slide the filler neck hose off the tank inlet. Position a drip pan under the connection as residual fuel may drain.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect vent line
   Locate the fuel tank vent line connected to the tank. This is typically a smaller diameter line near the filler neck. Release the connection by pressing the quick-disconnect tabs or loosening the clamp, depending on connection type. Place drip pan underneath to catch any fuel spillage.
   ⚠Fuel vapors will be released when disconnecting vent line. Ensure adequate ventilation.
5. 5

   Disconnect fuel supply and return lines
   Locate the fuel supply and return lines connected to the fuel pump module on top of the tank. These are metal lines with quick-disconnect fittings. Using the appropriate fuel line disconnect tool, depress the locking tabs and carefully pull each line straight off the pump module fittings. Cap or plug the open lines to prevent contamination. Place drip pan to catch residual fuel.
   ⚠️Even with pressure relieved, residual fuel will drain from lines. Keep ignition sources away and have drip pan positioned.
6. 6

   Disconnect fuel pump electrical connector
   Locate the electrical connector for the fuel pump module on top of the tank. Press the locking tab and carefully disconnect the connector. Position the connector and wiring harness away from the tank to prevent damage during removal.
7. 7

   Support fuel tank
   Position a transmission jack or sturdy adjustable jack stand under the center of the fuel tank. Raise the jack until it makes firm contact with the tank bottom and is supporting the tank weight. Use a piece of wood between the jack and tank to distribute load and prevent tank damage. Ensure tank is stable and will not shift.
   ⚠️The tank must be adequately supported before removing straps. If support fails, the tank will fall and can cause severe injury.
8. 8

   Remove fuel tank straps
   Locate the two fuel tank straps that wrap around the bottom of the tank and bolt to the frame rails. Each strap has two mounting bolts securing it to the frame. Using a socket and wrench, remove the 4 mounting bolts (2 per strap). The driver side strap and passenger side strap can be removed in either order. Once all 4 bolts are removed, carefully lower the straps away from the tank. Inspect bolt threads and frame mounting points for corrosion or damage.
   ⚠Straps may be corroded and bolts may be seized. Apply penetrating oil and allow to soak if bolts are difficult to remove. Do not apply excessive force that could damage frame mounting threads.
9. 9

   Lower and inspect tank
   With straps removed and tank supported by jack, carefully lower the tank 4-6 inches to inspect all connections and ensure nothing remains attached. Verify all fuel lines, vent lines, electrical connectors, and filler neck are disconnected. If performing only strap replacement and not removing tank completely, leave tank in this lowered position for strap installation.
   ⚠Do not lower tank more than necessary. Excessive lowering may stress remaining connections or make reinstallation difficult.
10. 10

    Inspect and prepare mounting points
    With tank lowered, inspect the frame rail mounting points where strap bolts thread in. Use a wire brush to clean threads and remove any corrosion. Inspect the fuel tank mounting surface where straps contact the tank for damage, corrosion, or wear. Clean the strap contact area on the tank bottom. Inspect the old straps for cracking, elongation at bolt holes, or corrosion damage.
11. 11

    Position new fuel tank straps
    Position the new driver side strap over the tank, aligning it with the frame rail mounting holes. The strap should wrap around the bottom of the tank with the mounting ends pointing upward toward the frame. Repeat for the passenger side strap. Ensure straps are not twisted and are positioned symmetrically on both sides of the tank.
12. 12

    Raise tank and install strap bolts
    Using the transmission jack, carefully raise the fuel tank until the strap mounting holes align with the frame rail threaded holes. Install all 4 strap mounting bolts finger-tight (2 per strap). Verify tank is centered and straps are positioned correctly before final tightening. Torque all 4 mounting bolts to 27 lb-ft in a cross pattern (alternate between driver and passenger side) to ensure even loading.
    ⚠Do not fully tighten one strap before starting the other. Alternate tightening to prevent tank misalignment.
13. 13

    Reconnect fuel pump electrical connector
    Route the fuel pump wiring harness to the connector on top of the fuel pump module. Align the connector and press firmly until the locking tab clicks into place. Gently tug on the connection to verify it is secure.
14. 14

    Reconnect fuel supply and return lines
    Remove caps or plugs from the fuel lines. Install new O-rings on the fuel pump module fittings, lubricating them lightly with clean gasoline. Push the fuel supply and return lines onto the module fittings until they click into place. Gently tug on each line to verify secure connection.
    ⚠Always use new O-rings on fuel line connections. Reused O-rings can leak and cause fire hazard.
15. 15

    Reconnect vent line and filler neck
    Reconnect the fuel tank vent line to the tank fitting, ensuring the quick-disconnect or clamp is fully secured. Slide the fuel filler neck hose onto the tank inlet and secure with the hose clamp, tightening until snug per manufacturer specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
16. 16

    Remove jack support and lower vehicle
    Carefully lower the transmission jack away from the fuel tank. Inspect all connections one final time to ensure everything is properly secured. Remove jack stands and lower the vehicle to the ground. Reconnect the negative battery cable.
17. 17

    Prime fuel system and check for leaks
    Turn the ignition key to the ON position (without starting engine) for 5 seconds, then OFF. Repeat this cycle 3-4 times to allow the fuel pump to prime the system. Crawl under the vehicle and visually inspect all fuel line connections, the filler neck, vent line, and pump module area for any signs of fuel leakage. If any leaks are detected, relieve fuel pressure again and correct the connection.
    ⚠️Do not start the engine if any fuel leaks are visible. Leaking fuel creates immediate fire hazard.

Reassembly

1. Reassembly is covered in the installation steps above
2. Ensure all fuel line connections are made with new O-rings and fully seated
3. Verify all hose clamps are tightened to specification
4. Double-check that strap mounting bolts are torqued to 27 lb-ft

Verification

• With vehicle on level ground, turn ignition to ON position multiple times and inspect all fuel connections for leaks
• Start engine and allow to idle for 2 minutes while monitoring for fuel odor or visible leaks under the vehicle
• Visually inspect fuel tank straps from under vehicle to confirm even contact with tank and proper alignment
• Test drive vehicle and listen for any unusual noises from fuel tank area that might indicate loose straps or tank movement
• After test drive, perform final inspection under vehicle for any fuel leaks or loose connections

More procedures for this vehicle