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Home >> Chrysler >> 2009 >> 300 Signature Series >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Delivery, Diesel >> Standard Procedure >> Draining Fuel Tank - Diesel >> Conventional Procedure

Conventional Procedure

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.
NOTE: Due to a one-way check valve installed into the fuel fill fitting at the tank, the tank cannot be drained at the fuel filler tube.
CAUTION: If the electric fuel pump module is not operating or the fuel level sending unit is not operating and the fuel level cannot be determined, the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle
  1. Verify the fuel level is below 5/8 of a tank.
  2. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE - DIESEL .
  3. Disconnect the negative battery cable.
    Fig 1: Rear Seat Up
    GC0080391Courtesy of CHRYSLER LLC
  4. Push the rear lower seat cushion up and back and remove the seat cushion.
    Fig 2: Foam Pad Under Seat
    GC0095733Courtesy of CHRYSLER LLC
  5. Fold back the foam pad covering the fuel pump module plastic access covers.
    Fig 3: Module Rubber Access Plug
    GC0080395Courtesy of CHRYSLER LLC
  6. Remove the left side fuel pump module plastic access cover.
    Fig 4: Left Side Module Electrical Connector
    GC0095734Courtesy of CHRYSLER LLC
  7. Disconnect the electrical connector (1) from the fuel pump module.
    Fig 5: Tool 9430 Left Side Module
    GC0095735Courtesy of CHRYSLER LLC
    CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.
    NOTE: Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
  8. Mark the fuel pump module orientation.
  9. Position the lock-ring remover/installer 9340 (1) into the notches on the outside edge of the lock-ring.
  10. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340 (1).
  11. Rotate the breaker bar counterclockwise and remove the lock-ring.
    Fig 6: Fuel Pump Module And 3/8 Inch Hose
    GC0095736Courtesy of CHRYSLER LLC
    CAUTION: Do not spill fuel into the interior of the vehicle.
    CAUTION: The lower reservoir of the fuel pump module must be drained before removal or fuel can spill into the interior of the vehicle.
  12. Lift the fuel pump module (1) up enough to push a 3/8 inch hose (2) into the fuel tank.
  13. Attach the opposite end of hose to the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved gas caddy.
  14. Using the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved gas caddy, evacuate the left side of the fuel tank.
    Fig 7: Access Cover - Right Side Module
    GC0095737Courtesy of CHRYSLER LLC
  15. Remove the right side auxiliary fuel pump module plastic access cover (1).
    Fig 8: Right Side Auxiliary Fuel Pump Module And Fuel Supply Line
    GC0095738Courtesy of CHRYSLER LLC
  16. Disconnect the fuel supply line (2) and the fuel return line at the right side auxiliary fuel pump module (1).
    Fig 9: Tool 9430 Right Side Module
    GC0095739Courtesy of CHRYSLER LLC
    CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.
    NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
  17. Mark the auxiliary fuel pump module orientation.
  18. Position the lock-ring remover/installer 9340 (1) into the notches on the outside edge of the lock-ring (2).
  19. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340 (1).
  20. Rotate the breaker bar counterclockwise and remove the lock-ring.
    Fig 10: 3/8 Inch Hose
    GC0095740Courtesy of CHRYSLER LLC
    CAUTION: Do not spill fuel into the interior of the vehicle.
    CAUTION: The lower reservoir of the fuel pump module must be drained before removal or fuel can spill into the interior of the vehicle.
  21. Lift the auxiliary fuel pump module up enough to push a 3/8 inch hose (1) into the fuel tank.
  22. Attach the opposite end of hose to the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved gas caddy.
  23. Using the Fuel Chief Gas Caddy 320-FC-P30-A or an OSHA approved gas caddy, evacuate the right side of the fuel tank.
  24. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE - DIESEL .
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