Fuel Tank: 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. Remove fuel tank filler tube cap.
2. Perform FUEL SYSTEM PRESSURE RELEASE PROCEDURE  .
3. Disconnect negative battery cable at battery.
4. Disconnect quick-connect fuel line at fuel rail. Refer to QUICK-CONNECT FITTINGS  for procedures.
5. The hose from the gasoline draining station must be adapted into the 5/16" quick-connect fitting on disconnected fuel line. One way to accomplish this is to obtain a 5/16" test fitting such as from Snap-On(R) Fuel Injection Adapter Set # FIDA44. Snap the fitting into the disconnected fuel line and attach hose from gasoline draining station.
6. 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.
7. Raise vehicle and remove splash shield in front of left/rear wheelhouse.
8. Remove hose clamps and disconnect rubber fill and vent hoses ( Fig 2 ) at fill and vent tubes ( Fig 1 ). Do not disconnect these hoses at fuel tank end.
   Fig 1: Removing Fuel Fill And Vent Tubes (Without ORVR System)

   Courtesy of DAIMLERCHRYSLER CORP.
9. If equipped with a 2-piece driveshaft, the crossmember located below the fuel tank must be removed.
   1. Remove bolts/nuts securing driveshaft 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.
   4. 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.
   5. Remove crossmember from vehicle.
   6. Remove remaining rivet material from cross-member and vehicle frame.
10. If equipped, remove fuel tank skid plate.
11. Place and secure a transmission jack under center of fuel tank and apply slight pressure.
    Fig 2: Removing Fuel Tank And Hoses (Without ORVR System)

    Courtesy of DAIMLERCHRYSLER CORP.
12. Remove two tank mounting nuts from mounting straps ( Fig 3 ). Position tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank.
13. Clean quick-connect fitting ( Fig 4 ) of any dirt/contaminants before removal.
14. Disconnect fuel supply line ( Fig 4 ) from fuel filter/fuel pressure regulator fitting at top of tank. Refer to QUICK-CONNECT FITTINGS  for procedures.
15. Disconnect fuel vapor line(s) from fuel tank check valve(s) at top of tank.
16. Disconnect electrical connector ( Fig 4 ) at pump module at top of tank.
17. Lower tank from vehicle. On certain models, the tank must first be moved rearward, and then downy for removal.
18. Remove tank from hydraulic jack.
19. If fuel pump module requires service, Refer to FUEL PUMP MODULE REMOVAL INSTALLATION  .
20. If fill and vent hoses are to be removed from tank, note their position on fuel tank fittings before removal.
    Fig 3: Removing Fuel Tank Mounting

    Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Removing Fuel Tank Top (Except ORVR)

    Courtesy of DAIMLERCHRYSLER CORP.

2-Door Models With ORVR System 

1. Remove fuel tank filler tube cap.
2. Perform FUEL SYSTEM PRESSURE RELEASE PROCEDURE  .
3. Disconnect negative battery cable at battery.
4. Drain fuel tank by using an approved gasoline draining station. Draining is done through the fuel fill tube. 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.
5. Raise vehicle and remove splash shield in front of left/rear wheelhouse.
6. Remove hose clamp and disconnect fill hose at tank fill fitting ( Fig 5 ).
7. Disconnect vent line ( Fig 5 ) at fuel fill tube.
8. If equipped with a 2-piece driveshaft, the crossmember located below the fuel tank must be removed.
   1. Remove bolts/nuts securing driveshaft 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.
   4. 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.
   5. Remove crossmember from vehicle.
   6. Remove remaining rivet material from cross-member and vehicle frame.
9. If equipped, remove fuel tank skid plate.
10. Place and secure a transmission jack under center of fuel tank and apply slight pressure.
11. Remove two tank mounting nuts from mounting straps ( Fig 3 ). Position tank mounting straps to side of vehicle and lower tank just enough to allow access to Connections at top of tank.
12. Clean quick-connect fitting ( Fig 5 ) of any dirt/contaminants before removal.
    Fig 5: Removing Fuel Tank Top Components (With ORVR System)

    Courtesy of DAIMLERCHRYSLER CORP.
13. Disconnect fuel supply line ( Fig 5 ) from fuel/filter/fuel pressure regulator fitting at top of tank. Refer to QUICK-CONNECT FITTINGS  for procedures.
14. Disconnect electrical connector at pump module at top of tank.
15. Lower tank from vehicle. On certain models, the tank must first be moved rearward, and then down, for removal.
16. Remove tank from hydraulic jack.
17. If fuel pump module requires service, Refer to FUEL PUMP MODULE REMOVAL INSTALLATION  .