Steps Involved:
1. Gather Necessary Parts and Tools: You'll need the new fuel tank (and sender unit if replacing that as well), new fuel lines (flexible and rigid), new fuel line clamps, gaskets (for the tank to the car's body), jack stands, jack, wrenches (various sizes), sockets, possibly a torque wrench, safety glasses, gloves, and rags. A helper is recommended.
2. Vehicle Preparation: Safely raise and support the rear of the vehicle using jack stands. This provides ample working space under the car. Remember to properly secure the vehicle on jack stands.
3. Drain Existing Fuel: If replacing the tank, siphon or drain any remaining fuel from the old tank into an appropriate container. Dispose of the old fuel properly according to local regulations.
4. Remove Old Fuel Tank: This involves disconnecting the fuel lines (mark them to know where they go!), the fuel tank filler neck, and the tank straps or mounting hardware. The process will vary slightly depending on the specific model of your Dart. You may need to loosen or remove some surrounding components to gain access. Take photos as you go to help with reassembly.
5. Clean the Area: Remove any dirt, debris, or rust from the area where the new tank will be mounted.
6. Install New Fuel Tank: Carefully lower the new fuel tank into place, ensuring the gaskets are correctly seated. Secure it using the straps or mounting brackets. Tighten hardware to manufacturer specifications (consult your repair manual or a torque spec chart).
7. Connect Fuel Lines: Carefully reconnect the fuel lines, making sure they are securely clamped. Double-check your markings to ensure correct connection.
8. Connect Filler Neck: Reattach the filler neck and ensure a secure seal.
9. Lower Vehicle: Carefully lower the vehicle from the jack stands.
10. Check for Leaks: Before driving, visually inspect all connections for leaks. Start the engine and check for leaks again. Pay close attention to the area around the tank and connections.
11. Test Drive: After confirming no leaks, take a short test drive to ensure proper operation.
Important Considerations:
* Repair Manual: A factory service manual specific to your 1974 Dodge Dart is invaluable. It provides detailed diagrams and instructions for your exact model.
* Safety: Gasoline is highly flammable. Work in a well-ventilated area, away from open flames or sparks. Use appropriate safety equipment.
* Fuel Line Material: Use fuel-resistant lines that meet or exceed the specifications for your vehicle.
* Torque Specifications: Over-tightening or under-tightening bolts can cause damage. Use a torque wrench if possible to ensure correct tightening.
This is a general outline. The specific steps and difficulties may vary depending on your Dart's exact configuration. Consult a repair manual for detailed instructions tailored to your vehicle. If you are not comfortable performing this task yourself, take your car to a qualified mechanic.
