Fuel Tank: Installation

If necessary, install fuel pump module to fuel tank. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP MODULE - INSTALLATION) .

Fig 1: 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)

Place fuel tank into skid plate. Wrap straps around tank with strap studs inserted through holes in skid plate. Tighten strap nuts (5) to attain 30 mm (+/-2 mm) between bottom of nut to end of strap stud. See Fig 1. Do not over tighten nuts.
Install two protective caps (6) to tank strap studs.
Connect fuel fill hose at tank. Tighten hose clamp.
Raise skid plate/fuel tank assembly into position on body while carefully guiding plastic vapor lines and fill hose.

Install four skid plate mounting nuts (1) at rear of tank. See Fig 1. Tighten to 16 N.m (141 in. lbs.) torque.

Fig 2: Fuel Tank Mounting Nuts - Front

Courtesy of DAIMLERCHRYSLER CORP.

1 - FRONT SKID PLATE NUTS (3)

2 - SKID PLATE

3 - ACCESS HOLE

Install three skid plate mounting nuts (1) at front of tank. See Fig 2. Tighten to 16 N.m (141 in. lbs.) torque.

Remove tank jacking device.

Fig 3: Identifying ORVR Components

Courtesy of DAIMLERCHRYSLER CORP.

1 - EVAP CANISTER

2 - NVLD FILTER

3 - NVLD PUMP

4 - VAPOR LINES

5 - FLOW VALVE

6 - TOP OF FUEL TANK)

Carefully connect the vapor line (4). See Fig 3. Be very careful not to bend or kink the vapor lines. If lines leak, a Diagnostic Trouble Code (DTC) will be set.

Fig 4: EVAP Canister/NVLD Pump Location

Courtesy of DAIMLERCHRYSLER CORP.

1 - RIGHT/REAR FENDER (WHEELHOUSE)

2 - BRACKET

3 - EVAP CANISTER

Install EVAP canister bracket (2). See Fig 4.
Install wheelhouse liner at right/rear wheel.
Install right/rear tire/wheel.
Connect electrical connector at of fuel tank.

Connect vapor line at left/front of fuel tank.

Fig 5: 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	-

Connect quick-connect fitting to fuel supply fitting (2). See Fig 5. (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .

Use a new plastic tie wrap to secure rear axle vent hose to fuel fill hose.

Fig 6: Fuel Fill Hose At Body

Courtesy of DAIMLERCHRYSLER CORP.

1 - FILLER HOSE CLAMP

2 - BEZEL

3 - FUEL FILLER CAP

4 - BEZEL SCREWS

5 - FUEL FILLER HOSE

6 - FUEL TANK

Position fuel fill bezel to body. Install the screws (4) and tighten. See Fig 6.
Fill fuel tank. Install filler cap.
Connect negative battery cable to battery.
Start vehicle and inspect for leaks.