Plastic HDPE Fuel Tank for Jeep Grand Cherokee 2005–2010 3.0 CRD Diesel

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

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

Safety First

• Work outside or in a very well-ventilated space—no sparks, no smoking, no heaters. Keep a Class
• B fire extinguisher within reach.
• Run the tank as close to empty as you can to make it lighter.
• Disconnect the negative battery cable before you begin.
• Wear fuel-rated gloves and eye protection. Use only approved fuel containers if you need to
  drain fuel.

Tools & Materials

• Floor jack + a wide wooden pad (or transmission/motorcycle jack) and 4 sturdy jack stands
• Basic metric socket set, extensions, and wrenches
• Flat screwdriver/pick for hose clamps and quick-connect tabs
• Line disconnect tools (for quick-connect fuel fittings)
• Pliers for spring clamps, a few fuel-resistant caps/plugs, rags
• Pen/labels to mark hoses; penetrating oil for rusty hardware
• New tank (diesel-specific) and new locking ring/O-ring for the pump/sender (recommended)
• Optional: new straps and skid-plate hardware if yours are rusty

Preparation

1. Lower the fuel level (drive it down). Leave the fuel cap on for now.
2. Disconnect the battery (negative terminal).
3. Raise and support the rear on jack stands. Remove the spare tire for working room.

Removal

1. Support the tank/skid with a jack and wooden pad.
2. Loosen filler and vent hose clamps and remove hoses.
3. Disconnect fuel lines with quick-disconnect tools and unplug tank harness.
4. Unbolt the skid plate assembly from the frame while the jack holds the weight.
5. Lower slightly to access remaining hoses, then disconnect them.
6. Lower fully and slide out the skid+tank assembly.

On the Bench

1. Remove the straps and lift the tank from the skid.
2. Transfer the sender/pump module: clean, mark orientation, remove locking ring, swap to new tank with a fresh O-ring.

Reinstallation

1. Set the new tank in the skid and refit straps evenly.
2. Raise the assembly under the Jeep, loosely reinstall skid-to-frame bolts.
3. Reconnect wiring, fuel lines, filler and vent hoses. Tighten skid bolts fully.
4. Torque filler-neck support bolts (~14 N·m / 10 ft-lb).

Prime & Start

1. Cycle ignition ON (do not crank) 3–4 times for 10–15 seconds each to purge air.
2. Optionally crack bleed screw on filter housing, cycle until fuel flows without bubbles, then
   close.
3. Start engine; may crank longer first time. Re-check for leaks.

Final Checks

1. Reinstall spare, lower vehicle, test drive, re-check for leaks.
2. Inspect/replace rusty skid plate if needed. Consider a plastic replacement tank for corrosion
   resistance.