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Fuel Tank: Removal

  1. Release the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  2. Disconnect the negative battery cable.
  3. Drain fuel tank dry into holding tank or a properly labeled GASOLINE  safety container.
  4. Raise vehicle and support.
  5. Disconnect the exhaust system between the catalytic converter and the muffler.
  6. Support the exhaust system with jack stands.
  7. Remove muffler hanger rubber groments. See Fig 1.
    Fig 1: Muffler Hanger
    GC0000420Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the center exhaust hanger rubber groments. See Fig 2 and Fig 3.
    Fig 2: Exhaust Hanger
    GC0000381Courtesy of DAIMLERCHRYSLER CORP.
    Fig 3: Exhaust Hanger Removed
    GC0000423Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove the rear portion of the exhaust system and set on floor.
  10. Disconnect the fuel tank electrical connector. See Fig 4.
    Fig 4: Fuel Tank Electrical Connector
    GC0000421Courtesy of DAIMLERCHRYSLER CORP.
  11. Disconnect the fuel line and EVAP line. See Fig 5.
    Fig 5: Fuel Supply Line And EVAP Lines
    GC0000427Courtesy of DAIMLERCHRYSLER CORP.
    1 - EVAP Line
    2 - Fuel Line
  12. Disconnect the vapor recirculation tube. See Fig 6.
    Fig 6: Fuel Tank Vapor Recirculation Tube
    GC0000422Courtesy of DAIMLERCHRYSLER CORP.
  13. Mark the driveshaft rear connection. See Fig 7.
    Fig 7: Marking Driveshaft
    GC0000425Courtesy of DAIMLERCHRYSLER CORP.
  14. Disconnect the driveshaft rear connection. See Fig 8.
    Fig 8: Driveshaft Rear Connection
    GC0000380Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the driveshaft support/bearing. See Fig 9.
    Fig 9: Driveshaft Support/Bearing
    GC0000379Courtesy of DAIMLERCHRYSLER CORP.
  16. Support driveshaft on jack.
  17. Remove the left rear tire and splash shield.
  18. Remove the fuel filler tube from the rubber hose at fuel tank. See Fig 10 and Fig 11.
    Fig 10: Fuel Filler Tube
    GC0000424Courtesy of DAIMLERCHRYSLER CORP.
    Fig 11: Filler Tube To Rubber Hose
    GC0000426Courtesy of DAIMLERCHRYSLER CORP.
  19. Support the fuel tank with a transmission jack.
  20. Remove the 2 fuel tank straps. See Fig 12.
    Fig 12: Fuel Tank Straps
    GC0000431Courtesy of DAIMLERCHRYSLER CORP.
  21. Lower fuel tank
  22. Drain Fuel Tank, use an approved GASOLINE draining station.
  23. Remove tank from vehicle. See Fig 13.
    Fig 13: Fuel Tank Assembly
    GC0000382Courtesy of DAIMLERCHRYSLER CORP.
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