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Fuel Tank: Removal

  1. Release fuel system pressure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE  in this section.
  2. Remove the battery cover and disconnect negative battery cable.
    NOTE: The trunk panel (Fig 1 ) will have to be cut to remove the fuel tank.
    Fig 1: Identifying Trunk Panel
    G03588139Courtesy 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.
    Fig 2: Marking Replacement Panel
    G03588140Courtesy of DAIMLERCHRYSLER CORP.
  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 Closeout Panel Hole For Fuel Tank
    G03588141Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Cutting Closeout Panel Hole For Fuel Tank
    G03588142Courtesy of DAIMLERCHRYSLER CORP.
    Fig 5: Removing Closeout Panel For Fuel Tank
    G03588143Courtesy of DAIMLERCHRYSLER CORP.
  6. Fuel tank and the EVAP system (Fig 6 ).
    Fig 6: Identifying Fuel Tank & EVAP Canister
    G03588144Courtesy 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 Fasteners
    G03588145Courtesy of DAIMLERCHRYSLER CORP.
    Fig 8: Removing Convertible Top Fasteners
    G03588146Courtesy of DAIMLERCHRYSLER CORP.
  9. Lift the top up and disconnect the heated back glass electrical connector (Fig 9 ) from both sides of the glass.
    Fig 9: Disconnecting Back Glass Electrical Connector
    G03588147Courtesy of DAIMLERCHRYSLER CORP.
  10. Pull top forward and out of the way.
  11. Roll deck lid carpet forward and out of the way.
    NOTE: Be careful the sealer on the cover will make it difficult to remove the cover.
  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.
    Fig 10: Locating Fuel Pump Module Cover
    G03588148Courtesy of DAIMLERCHRYSLER CORP.
    Fig 11: Removing Fuel Pump Module Cover And Rivets
    G03588149Courtesy of DAIMLERCHRYSLER CORP.
  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: Locating Fuel Pump Module Foam Block
    G03588150Courtesy of DAIMLERCHRYSLER CORP.
    Fig 13: Removing Fuel Pump Module Foam Block
    G03588151Courtesy of DAIMLERCHRYSLER CORP.
  15. Clean the area round the fuel pump module (Fig 14 ).
    Fig 14: Cleaning Area Round Fuel Pump Module
    G03588152Courtesy 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 Connections At Fuel Pump Module
    G03588153Courtesy of DAIMLERCHRYSLER CORP.
  19. Use Special Tool: #6856 to remove fuel pump module locknut (Fig 16 )
    Fig 16: Removing Fuel Pump Module Locknut Using Special Tool
    G03588154Courtesy 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 Fuel Tank Through Fuel Pump Module Hole
    G03588155Courtesy 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
    G03588156Courtesy of DAIMLERCHRYSLER CORP.
    Fig 19: Removing Filler Tube
    G03588157Courtesy of DAIMLERCHRYSLER CORP.
  26. Disconnect the vapor line at fuel filler tube (Fig 20 ).
    Fig 20: Disconnecting Vapor Line At Fuel Filler Tube
    G03588158Courtesy 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
    G03588159Courtesy of DAIMLERCHRYSLER CORP.
  30. Disconnect the ground strap from frame (Fig 22 ).
    Fig 22: Disconnecting Ground Strap From Frame
    G03588160Courtesy of DAIMLERCHRYSLER CORP.
  31. Disconnect the LDP electrical connector from pump (Fig 23 ).
    Fig 23: Disconnecting LDP Electrical Connector From Pump
    G03588161Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove the liquid separator (Fig 24 ) from the top of the EVAP canister.
    Fig 24: Removing Liquid Separator
    G03588162Courtesy 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: Pulling Wiring Harness
    G03588163Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: You may have to trim some of the trunk panel to make room for removal of fuel tank.
  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 ).
    Fig 26: Pulling Fuel Tank
    G03588164Courtesy of DAIMLERCHRYSLER CORP.
    Fig 27: Disconnecting Vacuum Connection
    G03588165Courtesy of DAIMLERCHRYSLER CORP.
  35. Remove the fuel tank from vehicle (Fig 28 ) and (Fig 29 ).
    Fig 28: Removing Fuel Tank From Vehicle
    G03588166Courtesy of DAIMLERCHRYSLER CORP.
    Fig 29: Removing Fuel Tank Assembly
    G03588167Courtesy 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
    G03588168Courtesy of DAIMLERCHRYSLER CORP.
    Fig 31: Removing Fuel Tank & Heat Shield
    G03588169Courtesy of DAIMLERCHRYSLER CORP.
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