Fuel Tank Replacement (Cutaway Van Rear Tank)

FUEL TANK REPLACEMENT (CUTAWAY VAN REAR TANK)

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to Vehicle Lifting.
5. Loosen the fuel fill hose clamp (2).
6. Disconnect the fuel fill hose from the fuel tank (1).




7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
8. Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes.
9. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.




10. With the aid of an assistant, support the fuel tank.
11. Remove the attaching bolts (4) from the fuel tank strap.
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel tank insulators.
2. Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank.




3. With the aid of an assistant, position and support the fuel tank.
4. Raise the fuel tank slightly.
5. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
6. Raise the tank fully.
7. Install the fuel tank straps (3).
8. Install the new attaching bolts (4) to the fuel tank strap.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

Tighten the bolts to 20.5 N.m (15 lb ft).




9. Remove the caps from the fuel and EVAP pipes.
10. Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes.




11. Connect the fuel fill hose to the fuel tank (1).

Tighten the fuel fill hose clamp (2) to 2.75 N.m (24 lb in).

12. Lower the vehicle.
13. Refill the fuel tank.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.