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Fuel Tank: Removal

  1. Release fuel system pressure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE  .
  2. Remove the battery cover and disconnect negative battery cable.
    3. NOTE: The trunk panel (Fig 1 ) will have to be cut to remove the fuel tank.
    Fig 1: Removing Trunk Panel
    G02682122Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: Marking Hole For Rivet
    G02682123Courtesy of DAIMLERCHRYSLER CORP.
  3. Put access panel in place and scribe the outline of the panel (Fig 2 ). Mark the hole for the rivet that hold the panel in place.
  4. Remove the panel and scribe a line about a 1/2 inch in from the panel outline.
  5. Cut closeout panel hole for fuel tank (Fig 3 ) and (Fig 4 ) and panel removed (Fig 5 ).
    Fig 3: Cutting Panel (1 Of 2)
    G02682124Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Cutting Panel (2 Of 2)
    G02682125Courtesy of DAIMLERCHRYSLER CORP.
    Fig 5: Removing Panel
    G02682126Courtesy of DAIMLERCHRYSLER CORP.
  6. Fuel tank and the EVAP system (Fig 6 ).
    Fig 6: Identifying Fuel Tank & EVAP Canister
    G02682127Courtesy of DAIMLERCHRYSLER CORP.
  7. Drill holes (17 holes).
  8. Remove the convertible top fasteners (15 nuts) (Fig 7 ) and (Fig 8 ).
    Fig 7: Removing Convertible Top Attachment
    G02682128Courtesy of DAIMLERCHRYSLER CORP.
    Fig 8: Removing Convertible Fastener
    G02682129Courtesy of DAIMLERCHRYSLER CORP.
  9. Lift the top up and disconnect the heated back glass electrical connector (Fig 9 ) from both sides of the glass.
  10. Pull top forward and out of the way.
    Fig 9: Disconnecting Back Glass Electrical Connector
    G02682130Courtesy of DAIMLERCHRYSLER CORP.
  11. Roll deck lid carpet forward and out of the way.
    12. NOTE: Be careful the sealer on the cover will make it difficult to remove the cover.
    Fig 10: Removing Fuel Pump Module Cover
    G02682131Courtesy of DAIMLERCHRYSLER CORP.
    Fig 11: Removing Cover And Rivets
    G02682132Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove the 4 rivets from the fuel pump module cover (Fig 10 ) and (Fig 11 ). You may have to knock out the center pin with a punch.
  13. Using a scraper or long knife cut the sealer under the cover to remove it from the vehicle.
  14. Remove the foam block from the top of the fuel pump module (Fig 12 ) and (Fig 13 ).
    Fig 12: Removing Pump Module Foam Block
    G02682133Courtesy of DAIMLERCHRYSLER CORP.
    Fig 13: Removing Foam Block
    G02682134Courtesy of DAIMLERCHRYSLER CORP.
  15. Clean the area round the fuel pump module (Fig 14 ).
    Fig 14: Cleaning Area Round Fuel Pump Module
    G02682135Courtesy of DAIMLERCHRYSLER CORP.
  16. Mark fuel pump module location on tank.
  17. Unlock and disconnect the electrical connector from the fuel pump module.
  18. Disconnect the fuel line, wrap shop towels around ends of fuel supply line (Fig 15 ).
    Fig 15: Disconnecting Electrical & Fuel Connection
    G02682136Courtesy of DAIMLERCHRYSLER CORP.
  19. Use Special Tool #6856 to remove fuel pump module locknut (Fig 16 ).
    Fig 16: Removing Fuel Pump Module Lock Ring
    G02682137Courtesy of DAIMLERCHRYSLER CORP.
  20. Lift module up to remove being careful not to spill the residual fuel that is left in it. The float arm of the level sensor catches on the inside of the fuel tank while removing the module. Tilt the module assembly to one side while removing it. Discard old seal.
  21. Drain the fuel tank through the fuel pump module hole (Fig 17 ).
    Fig 17: Draining Tank
    G02682138Courtesy of DAIMLERCHRYSLER CORP.
  22. Raise and support the vehicle.
  23. Remove the right rear tire.
  24. Remove the right rear splash shield.
  25. Remove the fuel filler tube from fuel tank (Fig 18 ) and (Fig 19 ).
    Fig 18: Removing Filler Neck Clamp
    G02682139Courtesy of DAIMLERCHRYSLER CORP.
    Fig 19: Removing Filler Tube
    G02682140Courtesy of DAIMLERCHRYSLER CORP.
  26. Disconnect the vapor line at fuel filler tube (Fig 20 ).
    Fig 20: Disconnecting Fuel Filler Tube Vent
    G02682141Courtesy of DAIMLERCHRYSLER CORP.
  27. Remove the fastener for fuel tank strap.
  28. Lower vehicle.
  29. Remove the left side fuel tank strap nut and remove the strap (Fig 21 ).
    Fig 21: Removing Tank Strap
    G02682142Courtesy of DAIMLERCHRYSLER CORP.
  30. Disconnect the ground strap from frame (Fig 22 ).
    Fig 22: Disconnecting Ground Strap
    G02682143Courtesy of DAIMLERCHRYSLER CORP.
  31. Disconnect the LDP electrical connector from pump (Fig 23 ).
    Fig 23: Disconnecting Fuel Tank Connectors
    G02682144Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove the liquid separator (Fig 24 ) from the top of the EVAP canister.
    Fig 24: Removing Liquid Separator
    G02682145Courtesy of DAIMLERCHRYSLER CORP.
  33. Pull wiring harness (Fig 25 ) for heated back glass down and out of the way from the top of the fuel tank.
    Fig 25: Removing Wiring Harness
    G02682146Courtesy of DAIMLERCHRYSLER CORP.
    34. NOTE: You may have to trim some of the trunk panel to make room for removal of fuel tank.
    Fig 26: Removing Fuel Tank
    G02682147Courtesy of DAIMLERCHRYSLER CORP.
    Fig 27: Disconnecting Vacuum Connection
    G02682148Courtesy of DAIMLERCHRYSLER CORP.
  34. Pull fuel tank to the rear of vehicle (Fig 26 ) and disconnect the vapor lines from the top of the fuel tank (Fig 27 ).
  35. Remove the fuel tank from vehicle (Fig 28 ) and (Fig 29 ).
    Fig 28: Removing Tank
    G02682149Courtesy of DAIMLERCHRYSLER CORP.
    Fig 29: Removing Fuel Tank Assembly
    G02682150Courtesy of DAIMLERCHRYSLER CORP.
  36. Clean vehicle.
  37. Make sure that the fuel tank heat shield (Fig 30 ) and (Fig 31 ) is not damaged.
    Fig 30: Removing Fuel Tank Heat Shield
    G02682151Courtesy of DAIMLERCHRYSLER CORP.
    Fig 31: Removing Fuel Tank & Heat Shield
    G02682152Courtesy of DAIMLERCHRYSLER CORP.
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