Service Procedure

1. Release fuel system pressure using the following procedure:





a. Remove and save the two rear seat cushion retaining screws (Figure 1).

b. Remove and save the rear seat cushion.

c. Remove and save the seat cushion silencer pad.





d. Remove and save both plastic fuel pump module access covers
(Figure 2).

e. Disconnect the electrical connector at both fuel pump modules.

f. Start and run engine until it stalls.

g. Attempt restarting engine until it will no longer run.

h. Turn the ignition key to the "OFF" position.

i. Place the transmission shifter lever in the "Neutral" position.





2. Remove the air cleaner inlet snorkel (Figure 3).

3. Disconnect and isolate the negative battery cable (Figure 3).

4. Using a shop vacuum, clean the top of fuel pump modules and fuel tank to remove loose dirt and debris.





5. Disconnect the fuel hose from the left fuel pump module
(Figure 4).

CAUTION:
Wrap a shop towel around the fuel hoses to catch any gasoline spillage.





6. Using the Fuel Pump module Lock Ring Wrench 9340 or equivalent, remove and save the left side fuel pump module lock ring (Figure 5).

7. Drain the fuel from the fuel tank.

8. Raise and support the vehicle on an appropriate hoist.

9. For vehicles with skid plates, remove and save the fuel tank skid plates.

10. Separate the exhaust pipe behind the catalytic converter and
remove and save the engine exhaust system.

11. Remove and save the rear propeller shaft using the following procedure:





a. Mark the propeller shaft and installation (Figure 6).

CAUTION:
Never allow the propeller shaft to hang while connected to the Power Transfer Unit (PTU), rear driveline module flange or center support bearing. If the propeller shaft section is hung unsupported, damage may occur to the joints, boots and/or center bearing from over-angulation.

b. Remove and save the four rear propeller shaft-to-pinion flange retaining nuts (Figure 6).

c. Remove and save the three nuts from the center support heat shield.

d. Remove and save the center support heat shield.





e. Remove and save the two center support bearing retaining bolts
(Figure 7).

f. Slide the propeller shaft out of the PTU and remove the propeller shaft assembly.





12. Remove and save the stay brackets (Figure 8).

13. Tie the rear driveline module to the rear suspension crossmember.

14. Support the rear driveline module.

15. Remove and save the three rear driveline module mounting bolts and lower the rear driveline module from the suspension crossmember (Figure 8).

16. Remove and save the splash shield.

17. Disconnect the vapor canister hose.

18. Disconnect the filler tube recirculation vent hose and purge hose.

19. Disconnect the rubber fill hose from the fuel tank.

CAUTION:
There may be fuel in the fuel tank fill tube. Remove the hose carefully to reduce fuel splash.





20. Remove and save the parking brake cable mounting brackets
from the fuel tank straps (Figure 9).

21. Support the fuel tank with an appropriate transmission jack.

22. Remove and save the bolts from the fuel tank straps.





23. Carefully lower the original fuel tank from the vehicle (Figure 10).

24. Transfer the fuel pump modules and heat shield from the original tank to the new tank (Figure 10).

NOTE:
Be sure to use the new rubber O-rings supplied in the fuel tank kit.

25. Place and secure the new fuel tank onto the transmission jack.

26. Raise the new fuel tank into position.

27. Position the fuel tank straps. Tighten the fuel tank strap bolts to 35 ft.lbs. (47 Nm).

28. Remove the transmission jack from under the fuel tank.

30. Install the parking brake cable brackets to the fuel tank straps (Figure 9).

31. Connect the filler tube recirculation vent hose and purge hose.

32. Connect the rubber fuel fill hose to the fuel tank inlet port. Tighten the hose clamp to 35 in. lbs. (4 Nm).

33. Place the rear driveline module into position (Figure 8). Tighten the three mounting bolts to 75 ft.lbs. (102 Nm).





34. Install the stay brackets (Figure 11). Tighten the mounting bolts to 18 ft. lbs. (24 Nm).

35. Install the splash shield.

36. Install the propeller shaft. Tighten the two center support
bearing retaining bolts to 30 ft.lbs. (41 Nm) and the four propeller shaft-to-flange retaining nuts to 43 ft. lbs. (58 Nm) (Figure 6 and 7).





37. Install the center support heat shield (Figure 12). Tighten the retaining nuts to 15 ft.lbs. (21 Nm).

38. Install the exhaust system.

39. For vehicles with skid plates, install the fuel tank skid plates.

40. Remove the front suspension splash shield and check the Power Transfer Unit (PTU) fluid level. The fluid level should be even with the bottom of the PTU fill hole. After filling the PTU, tighten the fill plug to 24 ft.lbs. (32 Nm).

NOTE:
Use Mopar 80W-90 Gear & Axle lubricant (P/N 04874468).

41. Install the front suspension splash shield.

42. Lower the vehicle from the hoist.

43. Connect the electrical connector, and lock the connector, for the right and left fuel pump module.

44. Connect the fuel hose to the left fuel pump module.

45. Install both plastic fuel pump module access covers.





47. Install the seat cushion silencer pad (Figure 13).

48. Install the rear seat cushion. Tighten the two rear seat retaining screws securely (Figure 1).

49. Connect the negative battery cable.

50. Install the air cleaner inlet snorkel (Figure 3).

51. Fill the fuel tank with fuel that was removed in Step 7.

52. Open a wiTECH session and connect the wiTECH VCI pod to the vehicle data link connector located under the steering column.

53. Use the wiTECH scan tool to pressurize the fuel system and check for fuel leaks.

54. Using the wiTECH scan tool, clear all Diagnostic Trouble Codes (DTCs).

55. Remove the wiTECH VCI pod from the vehicle.