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Home >> Dodge and Ram >> 2012 >> Challenger SXT Plus >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Delivery, Gas >> Standard Procedure >> Draining Fuel Tank >> Alternative Procedure

Alternative Procedure

WARNING:

The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.

WARNING:

No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.

CAUTION:

The fuel level of the vehicle must be below 5/8 of a tank before using the "Alternative Procedure". If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

CAUTION:

If the electric fuel pump is not operating, and the fuel level is above 5/8 of a tank, the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

CAUTION:

If the fuel level sending unit is not operating, and the fuel level cannot be determined the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle.

Fig 1: Negative Battery Cable
GC0139402Courtesy of CHRYSLER GROUP, LLC
  1. Verify the fuel level is below 5/8 of a tank.
  2. Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
  3. Disconnect the negative battery cable (1).
    Fig 2: Pulling Rear Seat Up
    GC0080391Courtesy of CHRYSLER GROUP, LLC
  4. Push the rear lower seat cushion up and back and remove the seat cushion.
    Fig 3: Foam Pad Under Seat
    GC0095733Courtesy of CHRYSLER GROUP, LLC
  5. Fold back the foam pad covering the fuel pump module plastic access covers.
    Fig 4: Locating Plastic Access Cover
    GC0080395Courtesy of CHRYSLER GROUP, LLC
  6. Remove the left side fuel pump module plastic access cover.
    Fig 5: Left Side Module Orientation
    GC0095734Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the electrical connector from the fuel pump module.
    CAUTION:

    An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.

    Fig 6: Tool Left Side Module
    GC0095735Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

  8. Mark the fuel pump module orientation.
  9. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the outside edge of the lock ring.
  10. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
  11. Rotate the breaker bar counterclockwise and remove the lock ring.
    CAUTION:

    Do not spill fuel into the interior of the vehicle.

    CAUTION:

    The lower reservoir of the fuel pump module must be drained before removal or fuel can spill into the interior of the vehicle.

    Fig 7: Draining Left Side
    GC0095736Courtesy of CHRYSLER GROUP, LLC
  12. Lift the fuel pump module up enough to push a 3/8 inch hose into the fuel tank.
  13. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.
  14. Using the gas caddy, evacuate the left side of the fuel tank.
    Fig 8: Access Cover Right Side Module
    GC0095737Courtesy of CHRYSLER GROUP, LLC
  15. Remove the right side auxiliary fuel pump module plastic access cover (1).
    Fig 9: Right Side Module Orientation
    GC0095738Courtesy of CHRYSLER GROUP, LLC
  16. Disconnect the fuel supply line (2) at the auxiliary fuel pump module (1).
    CAUTION:

    An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.

    Fig 10: Tool Right Side Module
    GC0095739Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

  17. Mark the auxiliary fuel pump module orientation.
  18. Position the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1) into the notches on the outside edge of the lock ring (2).
  19. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1).
  20. Rotate the breaker bar counterclockwise and remove the lock ring.
    Fig 11: Draining Right Side
    GC0095740Courtesy of CHRYSLER GROUP, LLC
  21. Lift the auxiliary fuel pump module up enough to push a 3/8 inch hose (1) into the fuel tank.
  22. Attach the opposite end of this hose to an OSHA approved fuel storage tank such as the JohnDow Gas Caddy 320-FC-P30-A or equivalent.
  23. Using the gas caddy, evacuate the right side of the fuel tank.
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