All 4-Door Models or 2-Door Models Without 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.

The fuel tank cannot be drained through the fill or vent fittings at the top of the fuel tank. Two different procedures may be used to drain fuel tank (using an approved gasoline draining station, or using the DRB scan tool along with an approved gasoline draining station). Draining is done from the disconnected fuel line, at the fuel rail, with either procedure.
1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release procedure.
3. Disconnect negative battery cable at battery.
4. Disconnect quick-connect fuel line at fuel rail.
5. The hose from the gasoline draining station must be adapted into the 5/16" quick-connect fitting on disconnected fuel line. One way to accomplish this is to obtain a 5/16" test fitting such as from Snap-On (R) Fuel Injection Adapter Set # FIDA44. Snap the fitting into the disconnected fuel line and attach hose from gasoline draining station.
6. Operate the gasoline draining station to drain fuel tank. As an alternative procedure, the electric fuel pump may be activated. 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.
7. Raise vehicle and remove splash shield in front of left/rear wheel house.

Fuel Fill And Vent Tubes (Without ORVR System):

Fuel Tank And Hoses (Without ORVR System):

8. Remove hose clamps and disconnect rubber fill and vent hoses at fill and vent tubes. Do not disconnect these hoses at fuel tank end.
9. 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.
10. If equipped, remove fuel tank skid plate.
11. Place and secure a transmission jack under center of fuel tank and apply slight pressure.

Fuel Tank Mounting:

12. 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.

Fuel Tank Top (Except ORVR):

13. Clean quick-connect fitting of any dirt/contaminants before removal.
14. Disconnect fuel supply line from fuel filter/fuel pressure regulator fitting at top of tank.
15. Disconnect fuel vapor line(s) from fuel tank check valve(s) at top of tank.
16. Disconnect electrical connector at pump module at top of tank.
17. Lower tank from vehicle. On certain models, the tank must first be moved rearward, and then down, for removal.
18. Remove tank from hydraulic jack.
19. If fuel pump module requires service.
20. If fill and vent hoses are to be removed from tank, note their position on fuel tank fittings before removal.

INSTALLATION
1. If fuel pump module is being installed
2. Install fill and vent hoses to tank fittings.
3. Place and secure fuel tank to transmission jack.
4. Raise tank up enough to connect fuel line, electrical connector and vapor hoses to top of fuel tank.
5. 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.
6. Remove transmission jack.
7. If equipped, install fuel tank skid plate.
8. 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.
9. Install fill and vent hoses to fill and vent tubes.
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.