Fuel Delivery: Tank-Fuel: Removal

Release the fuel pressure, refer to the Fuel Pressure Release Procedure .
Disconnect negative battery cable.
NOTE: The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.

Fig 1: DRAINING FUEL
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Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.

Fig 2: REAR SEAT
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Remove the rear lower seat cushion.

Fig 3: REAR SEAT UP
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Push seat back and up to remove seat cushion.

Fig 4: FOAM PAD UNDER SEAT
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Fold back the foam pad covering access cover for modules.

Fig 5: ACCESS COVER RIGHT SIDE MODULE
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Remove plastic access covers from floor pan right side.

Fig 6: RIGHT SIDE MODULE ORIENTATION
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Disconnect the fuel supply line from module.
Mark the module orientation.

Fig 7: TOOL 9430 RIGHT SIDE MODULE
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Use special tool #9340 to remove right side module lock ring.

Fig 8: DRAINING RIGHT SIDE
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Drain fuel from right side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.

Fig 9: LEFT SIDE MODULE ORIENTATION
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Disconnect the electrical connector from left side module.
Mark the module orientation.

Fig 10: TOOL 9430 LEFT SIDE MODULE
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Use special tool #9340 to remove left side module lock ring.

Fig 11: DRAINING LEFT SIDE
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Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
Install both module temporally, hand tighten the lock ring to hold modules in place.
Raise vehicle and support.
Remove left rear tire.

Fig 12: SPLASH SHIELD
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Remove the inner splash shield.

Fig 13: VENT LINE
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Disconnect the filler tube vent line.

Fig 14: FILLER TUBE CLAMP REMOVED
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Remove clamp from filler tube.

Fig 15: FILLER TUBE DISCONNECTED
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Remove metal filler tube from rubber tube on fuel tank.
Remove the exhaust system, (Refer to EXHAUST SYSTEM ).
Remove the drive shaft, (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - REMOVAL)

Fig 16: SPLASH SHIELD DR SIDE
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Remove the left underbody splash shield.

Fig 17: SPLASH SHIELD PASS SIDE
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Remove the right underbody splash shield.

Fig 18: EVAP LINE
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Disconnect the EVAP line in the right rear wheel well.

Fig 19: VAPOR CONNECTION ON TANK
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Disconnect vapor line.

Fig 20: FUEL LINE DISCONNECTED
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Disconnect the fuel supply line.

Fig 21: TANK STRAPS
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Support fuel tank with transmission jack.
Fuel tank strap bolt locations.

Fig 22: TANK STRAP BOLTS
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Remove bolt for fuel tank strap.

Fig 23: TANK STRAP BOLTS
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Remove bolt for fuel tank strap.

Fig 24: TANK VENT LINE ROUTING
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Lower tank and pull filler tube vent line through bracket.

Fig 25: FUEL TANK ASSEMBLY

Courtesy of DAIMLERCHRYSLER CORP.

1 - Right Side Module

2 - Control Valve

3 - Left Side Module (Fuel Pump Module)

Lower Fuel tank and remove from vehicle.

Fig 26: MODULE DR SIDE
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Left Side Module (Fuel Pump Module).

Fig 27: MODULE PASS SIDE
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Right Side Module.

Fig 28: CONTROL VALVE
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Control Valve and lines.