Fuel Tank Replacement (Cutaway Van Rear Tank)

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

4. Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
5. Loosen the fuel fill hose clamp (2).
6. Disconnect the fuel fill hose from the fuel tank (1).




7. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
8. Disconnect the rear fuel and Evaporative Emission ([1][2]EVAP) pipes (2) at the chassis fuel and EVAP pipes.
9. Cap the fuel and [1][2]EVAP pipes in order to prevent possible fuel system contamination.




10. With the aid of an assistant, support the fuel tank.
11. Remove the fuel tank strap attaching bolts (4).
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
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 [1][2]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 [1][2]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 fuel sender and the fuel pressure sensor electrical connectors.
6. Raise the tank fully.
7. Install the fuel tank straps (3).

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.

8. Install the new fuel tank strap attaching bolts (4).

Tighten
Tighten the fuel tank strap attaching bolts to 20.5 N.m (15 lb ft).




9. Remove the caps from the fuel and [1][2]EVAP pipes.
10. Connect the rear fuel and [1][2]EVAP pipes (2) to the chassis fuel and EVAP pipes.




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

Tighten
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.
16.1. Turn the ignition ON for 2 seconds.
16.2. Turn the ignition OFF for 10 seconds.
16.3. Turn the ignition ON.
16.4. Inspect for fuel leaks.