Fuel Tank Draining

FUEL TANK DRAINING

Special Tool(s):

Special Tool(s)

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.
4. Release the fuel tank filler cap and position aside.







5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.

6. NOTE: When the fuel tank is completely full, this step will remove approximately 1/8 of the fuel from the fuel tank.

Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel remaining in the fuel tank filler pipe.







7. CAUTION: The fuel pump module, fuel level sensor and the fuel tank inlet spout are below the fuel level when the fuel tank is completely full. Make sure to drain any residual fuel from the fuel tank filler pipe prior to removing the fuel tank filler pipe clamp and hose.

Release the fuel tank filler pipe hose-to-fuel tank inlet spout clamp.
- To install, tighten to 3 Nm (27 lb-in).

8. NOTE: The fuel tank filler pipe may have some residual fuel remaining in it after draining. Upon disconnecting the fuel tank filler pipe hose, carefully drain the residual fuel into a suitable container.

Remove the fuel tank filler pipe hose from the fuel tank inlet spout.







9. Insert a suitable fuel drain tube into the fuel tank inlet spout.

10. NOTE: When draining a completely full fuel tank, this step will drain most of the fuel from the RH side of the fuel tank, and partially drain the LH side of the fuel tank, due to the siphoning effect from the fuel crossover tube.

Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.

Five Hundred, Montego
11. Remove the rear lower seat cushion.
- Release the latches and pull upward on the rear lower seat cushion and remove.

Freestyle
12. Position the second row seats to the forward folded position.
13. Release the 2 load floor support brackets and position the load floor upward.
14. Position the third row seats into the load floor.
15. Remove the 4 load floor support-to-floor pan retaining nuts.
- To install, tighten to 18 Nm (13 lb-ft).

16. Remove the 2 load floor support brackets.

All vehicles
17. Position the rear floor carpet and any padding or insulation covering the fuel level sensor access cover aside.
18. Remove the fuel level sensor access cover.
19. Disconnect the fuel level sensor electrical connector.

20. NOTE: Place absorbant pads in the general work area in case of fuel spillage.

Clean the surrounding area of the fuel level sensor mounting flange.







21. Install the special tool and remove the fuel level sensor lock ring.
22. Carefully position the fuel level sensor aside.







23. Install a suitable fuel drain tube into the fuel level sensor access hole in the fuel tank.
24. Completely drain the remaining fuel from the LH side of the fuel tank.