REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5 and 6
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.
- Disconnect the negative battery cable.
- Remove the fuel filler cap.
- Properly relieve the fuel system pressure, as outlined earlier in this section.
- Insert a fuel syphon hose into the fuel filler neck and push it into the fuel tank.
- Drain the fuel tank dry into a proper holding tank or a properly labeled gasoline safety container.
- Raise and safely support the vehicle.
- Disconnect both the fuel filler and vent rubber hoses at the fuel tank.
- Disconnect the supply lines from the: fuel pump module located on top of the fuel tank (1996), or the steel supply line (1997-99).
- Slide the fuel pump module electrical connector lock to the unlock position, then push down on the retainer and pull the connector off of the module.
- Place a transmission jack, or equivalent support fixture, under the fuel tank.
- With the tank supported by a transmission jack, or equivalent, remove the bolts and fuel tank mounting straps.
- Lower the fuel tank slightly. Carefully remove the filler hose from the tank.
- Lower the fuel tank. Disconnect the pressure relief/rollover valve hose at the front of the tank. Remove clamp, then remove the fuel filler tube vent hose. Remove the tank from the vehicle.
- Position the fuel tank onto the transmission jack. Connect the pressure relief/rollover valve hose. Connect the fuel filler tube vent hose and replace the clamp.
- Raise the tank into position and carefully work filler tube into the fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
- Feed the filler vent line through the frame rail, being very careful not to cross the lines.
- Tighten the fuel tank strap bolts to 40 ft. lbs. (54 Nm). Check to make sure that the tank straps are not twisted or bent. Remove the transmission jack.
- Attach the fuel pump/module electrical connector and place the retainer in the locked position.
- Lubricate the fuel line with clean 30W engine oil, then install the quick connect fitting. If necessary, refer to the quick-connect fitting information earlier in this section.
- Carefully lower the vehicle.
- Fill the fuel tank, install the filler cap, then connect the negative battery cable.
When performing the ASD fuel system test, the ASD relay will remain energized for either 7 minutes, until the test is completed, or until the ignition switch is turned to the OFF position.
- Pressurize the fuel system using the Chrysler DRB, or equivalent scan tool, to perform the ASD fuel system test. Check the fuel system for leaks.