Fuel Tank: Removal

This vehicle is equipped with an ORVR (On-Board Refueling Vapor Recovery) system. Because of this, the fuel tank may be drained the conventional way through the filler cap opening.

On this model, the fuel tank is mounted to the vehicle skid plate. The skid plate is mounted to vehicle body. The tank and skid plate are removed as 1 assembly.

1. Remove fuel filler cap.
2. Perform the STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE  Procedure.
3. Disconnect negative battery cable.
4. Using an approved portable gasoline siphon/storage tank, drain fuel from tank through filler cap opening.
5. Remove 8 screws retaining plastic fuel filler bezel to body. Remove plastic fuel filler bezel.
   Fig 1: Removing Fuel Fill Hose From Body

   Courtesy of DAIMLERCHRYSLER CORP.
6. To prevent contaminants from entering tank, temporarily install fuel cap to fill hoses.
7. Remove right/rear tire/wheel.
8. Remove wheelhouse liner at right/rear wheel.
9. Remove vertical support bracket to gain access to 2 ORVR vapor lines.
   Fig 2: Locating EVAP Canister/LDP

   Courtesy of DAIMLERCHRYSLER CORP.
10. Two vapor lines connect the fuel tank to the EVAP canister and Leak Detection Pump (LDP). This connection is made near the right/rear corner of the fuel tank. Carefully disconnect these 2 vapor lines near top of flow management valve. Be very careful not to bend or kink the vapor lines. If lines leak, a Diagnostic Trouble Code (DTC) will be set.
    Fig 3: Disconnecting ORVR Vapor Lines

    Courtesy of DAIMLERCHRYSLER CORP.
11. Cut plastic tie wrap securing rear axle vent hose to fuel fill hose.
12. Disconnect fuel tank electrical connector at left/front of fuel tank.
    Fig 4: Disconnecting Fuel Tank/Fuel Pump Module

    Courtesy of DAIMLERCHRYSLER CORP.
13. Disconnect 2 vapor lines at left/front of fuel tank.
14. Disconnect quick-connect fitting from fuel supply line at front of fuel tank. See QUICK CONNECT FITTING .
15. The fuel tank and skid plate are removed as an assembly. Centrally position a transmission jack (or equivalent lifting device) under skid plate/fuel tank assembly. Secure tank assembly to jack.
16. Remove three skid plate-to-body nuts at front of tank. Remove one of the nuts through access hole on skid plate.
    Fig 5: Removing Fuel Tank Mounting Nuts - Front

    Courtesy of DAIMLERCHRYSLER CORP.
17. Remove four skid plate-to-body nuts at rear of tank. Do not loosen tank strap nuts. 
    Fig 6: Removing Fuel Tank Mounting Nuts - Rear

    Courtesy of DAIMLERCHRYSLER CORP.
18. Lower the tank assembly.
19. If fuel pump module is to be removed, see FUEL PUMP MODULE .
20. Disconnect fuel filler hose at tank. Before disconnecting, mark and note the hose rotational position in relation to tank fitting.
21. To separate tank from skid plate, remove two protective caps at tank strap studs and remove tank strap nuts.
22. Remove both straps and remove tank from skid plate.