300, 300C & Magnum 2006-2008, Charger 2006-2008

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel pressure, refer to the (Fuel Pressure Release Procedure) in this section.
  4.  
  5. Disconnect negative battery cable.
    NOTE
    The fuel level of the vehicle must be below 5 / 8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.

  6.  
  7. Drain the partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.
  8.  
  9. Remove the rear lower seat cushion.
  10.  
  11. Push seat back and up to remove seat cushion.
  12.  
  13. Fold back the foam pad covering access cover for modules.
  14.  
  15. Remove plastic access covers from floor pan right side.
  16.  
  17. Disconnect the fuel supply line from module.
  18.  
  19. Mark the module orientation.
  20.  
  21. Use the special tool number 9340 to remove right side module lock ring.
  22.  
  23. Drain fuel from right side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
  24.  
  25. Disconnect the electrical connector from left side module.
  26.  
  27. Mark the module orientation.
  28.  
  29. Use special tool 9340 to remove left side module lock ring.
  30.  
  31. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
  32.  
  33. Install both module temporally, hand tighten the lock ring to hold modules in place.
  34.  
  35. Raise and support the vehicle.
  36.  
  37. Remove left rear tire.
  38.  
  39. Remove the inner splash shield.
  40.  
  41. Disconnect the filler tube vent line.
  42.  
  43. Remove clamp from filler tube.
  44.  
  45. Remove metal filler tube from rubber tube on fuel tank.
  46.  
  47. Remove the exhaust system.
  48.  
  49. Remove the drive shaft.
  50.  
  51. Remove the left underbody splash shield.
  52.  
  53. Remove the right underbody splash shield.
  54.  
  55. Disconnect the EVAP line in the right rear wheel well.
  56.  
  57. Disconnect vapor line.
  58.  
  59. Disconnect the fuel supply line.
  60.  
  61. Support fuel tank with transmission jack.
  62.  
  63. Fuel tank strap bolt locations.
  64.  
  65. Remove bolt for fuel tank strap.
  66.  
  67. Remove bolt for fuel tank strap.
  68.  
  69. Lower tank and pull filler tube vent line through bracket.
  70.  
  71. Lower Fuel tank and remove from vehicle.
  72.  
  73. If fuel tank is being replaced remove modules, control valve and lines.
  74.  

To install:

  1. If fuel tank was replaced install modules, control valve and lines.
  2.  
  3. Support fuel tank with transmission jack.
  4.  
  5. Raise tank and push filler tube vent line through bracket.
  6.  
  7. Install the bolts for fuel tank straps and tighten.
  8.  
  9. Connect vapor line.
  10.  
  11. Connect the fuel supply line.
  12.  
  13. Connect the EVAP line in the right rear wheel well.
  14.  
  15. Install the drive shaft.
  16.  
  17. Install the exhaust system.
  18.  
  19. Install metal filler tube to rubber tube on fuel tank.
  20.  
  21. Install clamp to filler tube and tighten
  22.  
  23. Connect the filler tube vent line.
  24.  
  25. Install the inner splash shield.
  26.  
  27. Install the left underbody splash shield.
  28.  
  29. Install the right underbody splash shield.
  30.  
  31. Install left rear tire.
  32.  
  33. Lower the vehicle.
  34.  
  35. Install module and align marks on the module for proper orientation.
  36.  
  37. Install the module lock-ring.
  38.  
  39. Use the special tool number 9340 to tighten left side module lock ring.
  40.  
  41. Connect the electrical connector to left side module and install plastic access cover.
  42.  
  43. Install module and align marks on the module for proper orientation.
  44.  
  45. Install the module lock-ring.
  46.  
  47. Use then special tool number 9340 to tighten right side module lock ring.
  48.  
  49. Connect the fuel supply line to module.
  50.  
  51. Install plastic access covers to floor pan right side.
  52.  
  53. Fold the foam pad covering access cover for modules back into place.
  54.  
  55. Install rear lower seat cushion
  56.  
  57. Fill the fuel tank.
  58.  
  59. Connect negative battery cable.
  60.  
  61. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.
  62.  

 
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