Fuel Delivery - Diesel: Tank-Fuel: Removal

Release the fuel pressure, refer to STANDARD PROCEDURE - FUEL SYSTEM 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
Courtesy of DAIMLERCHRYSLER CORP.
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
Courtesy of DAIMLERCHRYSLER CORP.
Remove the rear lower seat cushion.

Fig 3: Pulliing Rear Seat Up
Courtesy of DAIMLERCHRYSLER CORP.
Push seat back and up to remove seat cushion.

Fig 4: Foam Pad Under Seat
Courtesy of DAIMLERCHRYSLER CORP.
Fold back the foam pad covering access cover for modules.

Fig 5: Access Cover Right Side Module
Courtesy of DAIMLERCHRYSLER CORP.
Remove plastic access covers from floor pan right side.

Fig 6: Right Side Module Orientation
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the fuel supply line from module.
Mark the module orientation.

Fig 7: Tool 9430 Right Side Module
Courtesy of DAIMLERCHRYSLER CORP.
Use special tool #9340 to remove right side module lock ring.

Fig 8: Draining Fuel From Right Side Of Fuel Tank
Courtesy of DAIMLERCHRYSLER CORP.
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
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the electrical connector from left side module.
Mark the module orientation.

Fig 10: Removing/Installing Left Side Module Lock Ring Using Special Tool
Courtesy of DAIMLERCHRYSLER CORP.
Use special tool #9340 to remove left side module lock ring.

Fig 11: Draining Left Side
Courtesy of DAIMLERCHRYSLER CORP.
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: Locating Inner Splash Shield
Courtesy of DAIMLERCHRYSLER CORP.
Remove the inner splash shield.

Fig 13: Vent Line
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the filler tube vent line.

Fig 14: Remove/Install Filler Tube Clamp
Courtesy of DAIMLERCHRYSLER CORP.
Remove clamp from filler tube.

Fig 15: Remove/Install Filler Tube
Courtesy of DAIMLERCHRYSLER CORP.
Remove metal filler tube from rubber tube on fuel tank.
Remove the exhaust system, (Refer to REMOVAL )
Remove the drive shaft, (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - REMOVAL)

Fig 16: Remove/Install Left Splash Shield
Courtesy of DAIMLERCHRYSLER CORP.
Remove the left underbody splash shield.

Fig 17: Remove/Install Right Splash Shield
Courtesy of DAIMLERCHRYSLER CORP.
Remove the right underbody splash shield.

Fig 18: EVAP Line
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the EVAP line in the right rear wheel well.

Fig 19: Disconnect/Connect Vapor Line
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect vapor line.

Fig 20: Disconnect/Connect Fuel Line
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the fuel supply line.

Fig 21: Tank Straps
Courtesy of DAIMLERCHRYSLER CORP.
Support fuel tank with transmission jack.
Fuel tank strap bolt locations.

Fig 22: Tank Strap Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Remove bolt for fuel tank strap.

Fig 23: Tank Strap Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Remove bolt for fuel tank strap.

Fig 24: Tank Vent Line Routing
Courtesy of DAIMLERCHRYSLER CORP.

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: Left Side Module
Courtesy of DAIMLERCHRYSLER CORP.
Left Side Module (Fuel Pump Module).

Fig 27: Right Side Module
Courtesy of DAIMLERCHRYSLER CORP.
Right Side Module.

Fig 28: Control Valve
Courtesy of DAIMLERCHRYSLER CORP.
Control Valve and lines.