Removal (All 4-Door Models, Or 2-Door Models Without ORVR System)

The fuel tank cannot be drained through the fill or vent fittings at the top of the fuel tank. Two different procedures may be used to drain fuel tank (using an approved gasoline draining station, or using the DRB scan tool along with an approved gasoline draining station). Draining is done from the disconnected fuel line, at the fuel rail, with either procedure.

1. Disconnect negative battery cable at battery. Disconnect quick-connect fuel line at fuel rail. See FUEL LINE DISCONNECT FITTINGS .
2. The hose from the gasoline draining station must be adapted into the 5/16" disconnect fitting on disconnected fuel line. One way to accomplish this is to obtain a 5/16" test fitting such as from Snap-On® Fuel Injection Adapter Set (FIDA44). Snap the fitting into the disconnected fuel line and attach hose from gasoline draining station.
3. Operate the gasoline draining station to drain fuel tank. As an alternative procedure, the electric fuel pump may be activated. Refer to DRB scan tool for fuel pump activation procedures. Activate electric fuel pump, or gasoline draining station, and drain tank until empty. If electric fuel pump is not operating, the gasoline draining station must be used.
4. Raise vehicle and remove splash shield in front of left/rear wheelhouse.
5. Remove hose clamps and disconnect rubber fill and vent hoses at fill and vent tubes. See Fig 1 and Fig 2 . Do not disconnect these hoses at fuel tank end.
6. If equipped with a 2-piece driveshaft, the crossmember located below the fuel tank must be removed:
   1. Remove bolts/nuts securing drive shaft, center bearing carrier bracket to crossmember.
   2. Raise and support driveshaft and carrier bracket assembly using a length of rope.
   3. Center punch all rivets. Drill out rivets with a 3/8" drill bit. Do not use a larger bit, as holes in crossmember and vehicle frame may become too large.
   4. Remove crossmember from vehicle. Remove remaining rivet material from crossmember and vehicle frame.
7. If equipped, remove fuel tank skid plate. Place and secure a transmission jack under center of fuel tank and apply slight pressure.
8. Remove two tank mounting nuts from mounting straps. See Fig 3. Position tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank.
9. Clean disconnect fitting of any dirt/contaminants before removal. See Fig 4.
10. Disconnect fuel supply line from fuel filter/fuel pressure regulator fitting at top of tank. See FUEL LINE DISCONNECT FITTINGS .
11. Disconnect fuel vapor line(s) from fuel tank check valve(s) at top of tank. Disconnect electrical connector at pump module at top of tank. See Fig 4.
12. Lower tank from vehicle. On certain models, the tank must first be moved rearward, and then down, for removal. Remove tank from hydraulic jack.
13. If fuel pump module requires service, see FUEL PUMP MODULE . Fuel pump module is located on top of fuel tank. See Figure and Figure .
14. If fill and vent hoses are to be removed from tank, note their position on fuel tank fittings before removal.

Fig 1: Identifying Fuel Fill & Vent Tubes (Without ORVR System)

Courtesy of CHRYSLER CORP.

Fig 2: Identifying Fuel Tank Components & Hoses (Without ORVR System)

Courtesy of CHRYSLER CORP.

Fig 3: Mounting Fuel Tank

Courtesy of CHRYSLER CORP.

Fig 4: Identifying Fuel Tank Top (Without ORVR)

Courtesy of CHRYSLER CORP.

Fig 5: Identifying Fuel Tank Top (With ORVR System)

Courtesy of CHRYSLER CORP.