Tank, Fuel: Removal: Removal

WARNING:

The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

Fig 1: Identifying Fuel Fill Hose, Fuel Fill Hose Clamp & Tank

Courtesy of CHRYSLER GROUP, LLC

Remove fuel fill cap.
Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
Loosen the fuel fill hose clamp (2) at rear of tank (3) and disconnect fuel fill hose (1) from fuel tank.
NOTE:
There is a small flapper valve installed at the fuel tank filler opening.
Using an approved diesel fuel draining station, position a drain hose into the fuel fill hose opening and drain the fuel tank.

Fig 2: Fuel Tank Front & Quick-Connect Fittings
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Disconnect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.

Fig 3: Locating 2.8L Diesel Fuel Pump Module
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Disconnect the quick-connect fittings (6) and (8) for fuel vapor and vent lines at rear of tank. Refer to FITTING, QUICK CONNECT .

Fig 4: Identifying Skid Plates
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Remove the front transfer case skid plate bolts (2) and the rear bolts (3) and remove the transfer case skid plate (4).
Support fuel tank with a hydraulic jack.
NOTE:
The fuel tank skid plate and the fuel tank assembly are removed together. They share common fasteners.
Remove the two fuel tank mounting bolts at the front of fuel tank.
Remove the three tank mounting bolts at right side of fuel tank.
Remove the three tank mounting bolts at left side of fuel tank.

Fig 5: Locating 2.8L Diesel Fuel Pump Module
Courtesy of CHRYSLER GROUP, LLC
Partially lower tank to gain access to pump module electrical connector (4). Disconnect fuel pump module wire harness connector (4).
Continue lowering tank for removal.
Lift fuel tank from skid plate.
If the fuel pump module is to be replaced, remove fuel pump module from tank.