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 one assembly.

1. Remove fuel filler cap.
2. Perform the 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.
   Fig 1: FUEL FILL HOSE AT BODY

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - FILLER HOSE CLAMP

   2 - BEZEL

   3 - FUEL FILLER CAP

   4 - BEZEL SCREWS (8)

   5 - FUEL FILLER HOSE

   6 - FUEL TANK

5. Remove 8 screws (4) retaining plastic fuel filler bezel to body. Remove plastic fuel filler bezel (2). See Fig 1.
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.
   Fig 2: EVAP CANISTER/NVLD PUMP LOCATION

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - RIGHT/REAR FENDER (WHEELHOUSE)

   2 - BRACKET

   3 - EVAP CANISTER

9. Remove vertical support bracket (2) to gain access to ORVR vapor line. See Fig 2.
   Fig 3: ORVR VAPOR LINE

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - EVAP CANISTER

   2 - NVLD FILTER

   3 - NVLD PUMP

   4 - VAPOR LINES

   5 - FLOW VALVE

   6 - TOP OF FUEL TANK)

10. A vapor line (4) connects the fuel tank to the EVAP canister and NVLD pump. This connection is made near the right/rear corner of the fuel tank. Carefully disconnect this vapor line (4). See Fig 3. Be very careful not to bend or kink the vapor lines. If vapor lines leak, a Diagnostic Trouble Code (DTC) will be set.
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.
13. Disconnect 2 vapor lines at left/front of fuel tank.
    Fig 4: TOP OF FUEL TANK

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - FUEL PUMP MODULE LOCKRING	7 - SKID PLATE
    2 - FUEL SUPPLY LINE	8 - FUEL FILL FITTING
    3 - ELECTRICAL CONNECTOR	9 - FUEL VENT FITTING
    4 - VAPOR LINE	-
    5 - FUEL TANK MOUNTING STRAPS (2)	-
    6 - FUEL PUMP MODULE ASSEMBLY	-

14. Disconnect quick-connect fitting from fuel supply line at front of fuel tank. See Fig 4. Refer to QUICK CONNECT FITTING  for procedures.
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.
    Fig 5: FUEL TANK MOUNTING NUTS - FRONT

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - FRONT SKID PLATE NUTS (3)

    2 - SKID PLATE

    3 - ACCESS HOLE

16. Remove three skid plate-to-body nuts (1) at front of tank. Remove one of the nuts through access hole (3) on skid plate. See Fig 5.
    Fig 6: FUEL TANK MOUNTING NUTS - REAR

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - REAR SKID PLATE NUTS (4)

    2 - SKID PLATE

    3 - TANK STRAP STUD

    4 - TANK STRAP NUT

    5 - TANK STRAP NUTS (2)

    6 - PROTECTIVE CAPS (2)

17. Remove four skid plate-to-body nuts (1) at rear of tank. Do not loosen tank strap nuts.  See Fig 6.
18. Lower the tank assembly.
19. If fuel pump module is to be removed, refer to FUEL PUMP MODULE  for Removal.
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 (6) at tank strap studs and remove tank strap nuts. See Fig 6.
22. Remove both straps and remove tank from skid plate.