Dodge Durango

 Service Manual

Fuel System » Fuel delivery system » Removal and installation
Fuel tank

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF).

BEFORE DRAINING FUEL TANK, FUEL SYSTEM PRESSURE MUST BE RELEASED.

Two different procedures may be used to drain fuel tank (removing fuel vent hose at fuel tank or using DRB scan tool).

The quickest draining procedure involves removing fuel vent hose at fuel tank.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB scan tool for fuel pump  activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure in this group for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump is not operating, tank must be drained by removing fuel vent hose. Refer to following procedures.

REMOVAL

(1) Perform Fuel System Pressure Release procedure as described in this group.

(2) Disconnect negative battery cable at battery.

(3) Remove fuel tank filler tube cap.

(4) Raise vehicle on hoist.

(5) If equipped, remove fuel tank skid plate. Refer to Fuel Tank Skid Plate in Group 23, Body.

(6) Two rubber hoses (fuel filler and fuel vent hoses) connect the fuel tank fittings (at rear of tank) to the metal fuel fill tube assembly at body (Fig. 36).

Disconnect hose clamps (Fig. 36) at fuel fill tube assembly end of hoses and disconnect rubber hoses.

(7) Position a drain hose into the fuel vent hose (Fig. 36) and into tank.

(8) Drain fuel into an approved portable holding tank or a properly labeled gasoline safety container.

Fig. 36 Fuel Hoses at Rear of Fuel Tank

1 - CLAMPS

2 - L.R. SHOCK ABSORBER

3 - FUEL TANK

4 - CLAMPS

5 - FUEL VENT HOSE

6 - FUEL FILL HOSE

Fig. 37 Fuel Tank Mounting

1 - STRAP MOUNTING HOLES (2)

2 - TANK MOUNTING STUDS (2)

3 - TANK NUTS (2)

4 - FUEL TANK

5 - TANK STRAPS (2)

(9) Place and secure a transmission jack under center of fuel tank and apply slight pressure.

(10) Remove two tank mounting nuts from mounting straps (Fig. 37). Position tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank. To prevent fuel loss, be sure rear of tank is higher than front of tank when lowering.

(11) Clean quick-connect fittings (at top of fuel tank) of any dirt/contaminants before removal.

(12) Disconnect fuel supply line from fuel filter/ fuel pressure regulator fitting at top of tank. Refer to Quick-Connect Fittings for procedures.

(13) Disconnect rear fuel vapor line (EVAP line) from rollover valve at top/rear of tank.

(14) Disconnect front fuel vapor line (EVAP line) from rollover valve at fuel pump module.

(15) Disconnect electrical connector from pump module at top of tank.

(16) Lower tank from vehicle.

(17) Remove tank from hydraulic jack.

(18) If fuel pump module requires service, refer to Fuel Pump Module Removal/Installation.

INSTALLATION

(1) If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation. Be sure fuel filter/fuel pressure regulator inlet fitting is pointed towards front of vehicle.

(2) Place and secure fuel tank on top of transmission jack.

(3) Raise tank up enough to connect fuel line, electrical connector and both EVAP lines to top of fuel tank. Refer to Quick-Connect Fittings for fuel line procedures.

(4) Continue raising tank into position and install mounting straps and nuts. Tighten nuts to 27-54 N*m (20-40 ft. lbs.) torque. Do not over tighten mounting strap nuts.

(5) Remove transmission jack.

(6) Connect fill/vent hoses to fill/vent tube assembly.

(7) Tighten hose clamps at fill/vent hoses.

(8) If equipped, install fuel tank skid plate. Refer to Fuel Tank Skid Plate in Group 23, Body.

(9) Connect negative cable to battery.

(10) Refill fuel tank and install fill cap.

(11) Inspect all hoses and lines for leaks.

Fuel filter/fuel pressure regulator

Fuel pump module

Fuel pump inlet filter

Fuel gauge sending unit

Fuel injector rail-3.9/5.2/5.9L engines

Fuel injector rail-4.7L v-8 engine

Fuel injector(s)

Fuel tank

Fuel tank filler tube cap

Accelerator pedal

Throttle cable

Throttle cable-4.7L v-8 engine