Plastic (HDPE) fuel tank – Jeep Commander 2005-2010 3.0 CRD Diesel

Step-by-Step Guide to Replacing the Fuel Tank on a 2005–2010 Jeep Commander 3.0 CRD Diesel

Safety first: If you’re not comfortable working with fuel systems or heavy lifting, hire a professional.

Introduction

Replacing the fuel tank on a Jeep Commander 3.0 CRD Diesel (model years 2005–2010) is a moderately complex task that requires mechanical skills, appropriate tools, and safety precautions. This guide will walk you through the process step by step.

Tools and Equipment Required

• Safety glasses and gloves
• Jack and sturdy jack stands
• Wheel chocks
• Socket set and wrenches
• Screwdrivers (flathead and Phillips)
• Fuel line disconnect tool
• Drain pan and siphon pump
• Replacement fuel tank
• Torque wrench
• Shop towels/rags

Safety Precautions

• Work in a well-ventilated area away from sparks, flames, or open heat sources.
• Disconnect the negative battery terminal before starting.
• Properly relieve fuel system pressure before disconnecting any fuel lines.
• Use jack stands to safely support the vehicle at all times. Never rely solely on a jack.

Step-by-Step Procedure

1. Preparation

1. Park the vehicle on a flat, stable surface.
2. Place wheel chocks around the front tires.
3. Disconnect the negative battery cable.
4. Relieve pressure from the fuel system (via the fuel pump fuse/relay and running the engine until it stalls).

2. Drain the Fuel Tank

1. Safely siphon as much fuel as possible into an approved container using a siphon pump.
2. Place a drain pan underneath the tank to catch any residual fuel.

3. Raise and Support the Vehicle

1. Use a jack to raise the rear of the vehicle.
2. Place jack stands securely under the frame to support it.

4. Disconnect Fuel and Electrical Connections

1. Locate the fuel lines connected to the tank and disconnect them using the fuel line tool.
2. Disconnect the electrical connector(s) to the fuel pump/sending unit.

5. Remove Tank Straps and Shield

1. Support the fuel tank with a transmission jack or a sturdy floor jack with a wide base.
2. Remove the fuel tank shield (if equipped).
3. Loosen and remove the bolts securing the fuel tank straps.

6. Lower and Remove the Tank

1. Slowly lower the fuel tank while checking for any remaining connections.
2. Fully remove the tank from under the vehicle.

7. Transfer Components (if applicable)

1. If the replacement tank does not include a fuel pump or sending unit, carefully remove them from the old tank.
2. Install them into the new tank, ensuring proper seals and gaskets.

8. Install the New Fuel Tank

1. .Position the new tank on the jack.
2. Carefully raise it into place.
3. Reinstall the tank straps and torque bolts to manufacturer specifications.
4. Reinstall the tank shield (if equipped).

9. Reconnect Lines and Electrical Connections

1. Reconnect all fuel lines and ensure secure fittings.
2. Reconnect electrical connectors to the pump/sending unit.

10. Lower Vehicle and Refill Fuel

1. Carefully lower the vehicle to the ground.
2. Add fresh diesel fuel.
3. Reconnect the negative battery cable.

11. Test and Inspect

1. Turn the ignition key to the ON position (without starting) to prime the fuel system.
2. Check for leaks around connections.
3. Start the engine and let it idle.
4. Recheck for any leaks or warning lights.

Torque Specifications (Reference Only)

Fuel tank strap bolts: ~40–50 Nm (consult service manual for exact torque)

Conclusion
Replacing the fuel tank on a 2005–2010 Jeep Commander 3.0 CRD Diesel requires caution and attention to detail, but following this step-by-step guide will help ensure a safe and successful repair.