2-Door Models With CRVR System

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE DRAINING FUEL TANK, FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release procedure.
3. Disconnect negative battery cable at battery.
4. Drain fuel tank by using an approved gasoline draining station. Draining is done through the fuel fill tube. As an alternative procedure, the electric fuel pump may be activated. Refer to DRB Scan Tool for fuel pump activation procedures. Activate electric fuel pump, or gasoline draining station, and drain tank until empty. If electric fuel pump is not operating, the gasoline draining station must be used.
5. Raise vehicle and remove splash shield in front of left/rear wheel house.

Fuel Tank Top (With ORVR System):

6. Remove hose clamp and disconnect fill hose at tank fill fitting.
7. Disconnect vent line at fuel fill tube.
8. If equipped with a 2-piece driveshaft, the crossmember located below the fuel tank must be removed.
a. Remove bolts/nuts securing driveshaft center bearing carrier bracket to crossmember.
b. Raise and support driveshaft and carrier bracket assembly using a length of rope.
c. Center punch all rivets.
d. Drill out rivets with a 3/8" drill bit. Do not use a larger bit, as holes in crossmember and vehicle frame may become too large.
e. Remove crossmember from vehicle.
f. Remove remaining rivet material from cross-member and vehicle frame.
9. If equipped, remove fuel tank skid plate.
10. Place and secure a transmission jack under center of fuel tank and apply slight pressure.

Fuel Tank Mounting:

11. Remove two tank mounting nuts from mounting straps. Position tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank.
12. Clean quick-connect fitting of any dirt/contaminants before removal.
13. Disconnect fuel supply line from fuel filter/fuel pressure regulator fitting at top of tank.
14. Disconnect electrical connector at pump module at top of tank.
15. Lower tank from vehicle. On certain models, the tank must first be moved rearward, and then down, for removal.
16. Remove tank from hydraulic jack.
17. If fuel pump module requires service refer to fuel Pump Module Removal/Installation.

INSTALLATION
1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation.
2. Place and secure fuel tank to transmission jack.
3. Raise tank up enough to connect fuel supply line, electrical connector and ORVR vapor line to top of fuel tank.
4. Connect small vent line to fuel fill tube.
5. Connect fuel fill hose to tank.
6. Continue raising tank into position and install mounting straps and nuts. Tighten nuts to 27-54 Nm (20-40 ft. lbs.) torque. Do not over tighten mounting strap nuts.
7. Remove transmission jack.
8. If equipped, install fuel tank skid plate.
9. If equipped with a 2-piece driveshaft:
a. Obtain new bolts and nuts to secure cross-member to frame. Use the same OEM bolts/nuts that are used to secure the upper fuel tank cross-member to the vehicle frame.
b. Position crossmember to vehicle frame. Install bolts and tighten to 54 Nm (40 ft. lbs.) torque.
c. Position driveshaft and carrier bracket assembly to crossmember.
d. Install bolts and tighten to 54 Nm (40 ft. lbs.) torque.
10. Install splash shield in front of left/rear wheel house.
11. Connect negative cable to battery.
12. Refill fuel tank and install fill cap.
13. Inspect all hoses and lines for leaks.