Fuel Tank Replacement (Passenger/Cargo Van)
REMOVAL PROCEDURETools Required
J 3660B Fuel Sender Tool
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.
CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.
3. Raise the vehicle.
4. Remove the off-road shield, if applicable.
5. Loosen the filler neck hose clamp (2) at the fuel tank (1).
6. Disconnect the filler neck hose (3) from the fuel tank.
7. Support the fuel tank.
8. Remove the fuel tank bolts (4), straps (3) and the insulator strips, if applicable.
9. Slightly lower the fuel tank (2) and the fuel tank shield.
10. Disconnect the fuel feed and the vapor hoses.
11. Disconnect the electrical connections at the fuel sender assembly.
12. Lower the fuel tank and the fuel tank shield.
13. Use the J 36608 fuel sender tool in order to remove the fuel sender assembly and the seal ring. Discard the old seal ring.
14. Purge the tank if the tank is being repaired.
INSTALLATION PROCEDURE
1. Install a new seal ring.
2. Slightly raise the fuel tank and the fuel tank shield.
3. Use the J 36608 fuel sender tool in order to install the fuel sender assembly.
4. Reconnect the fuel feed and the vapor hoses.
5. Reconnect the electrical connector to the fuel sender assembly.
6. Raise the fuel tank fully.
7. Reinstall the fuel filler neck (3) to the fuel tank (1).
NOTE: Refer to Fastener Notice in Service Precautions.
8. Install the clamp (2).
Tighten
Tighten the clamp to 2.5 N.m (25 lb in)
NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is. reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.
9. Install the fuel tank brackets (3) with the insulator strips in place.
Tighten
Tighten the fuel tank bolts (4) to 45 N.m (33 lb ft).
10. Install the fuel tank off-road shield, if applicable.
11. Lower the vehicle.
12. Replenish the fuel in the fuel tank (2).
13. Reinstall the fuel tank filler cap.
14. Reconnect the batteries. If a memory retention device was not used, reset (to the extent possible) all of the devices that lost their memory after the battery was disconnected.
15. Inspect for leaks with the following procedure:
15.1. Turn ON the ignition for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Again, turn ON the ignition.
15.4. Inspect for any fuel leaks.