Fuel Tank Replacement (Passenger/Cargo Van)

REMOVAL PROCEDURE

Tools Required
J 39765 Fuel Sender Locknut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
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. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
4. Remove the fuel tank off-Road shield, if equipped.




5. Loosen the filler neck hose clamp (2) at the fuel tank (1), and disconnect the fuel tank filler neck from the fuel tank.




6. Support the fuel tank, and remove the tank straps and the insulator strips (3,4), if equipped.
7. Lower the fuel tank shield.




8. Lower the fuel tank (2). Disconnect the fuel feed and vapor hoses.
9. Disconnect the electrical connector at the sender.




10. Use the J 39765 in order to remove the fuel sender assembly and seal ring. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install the new seal ring, and use the J 39765 in order to reinstall the sender.
2. Raise the tank slightly, and reconnect the fuel feed hoses, the vapor hoses, and the electrical connections at the sender.
3. Raise the tank fully.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: You must properly position and align the fuel tank filler neck clamps, or the filler neck may become disconnected from the fuel tank.




4. Re-install the fuel tank filler neck (3) to the tank (1).

Tighten
Tighten the clamp to 2.75 N.m (24.3 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.

IMPORTANT: When you remove or replace the fuel tank, never reuse the fuel tank support fasteners. When you install the fuel tank, always use new fasteners.




5. Install the fuel tank brackets (3) with the insulator strips in place.

Tighten
Tighten the strap nuts to 20 N.m (15 lb ft).

6. Install the fuel tank off-road shield, if equipped.
7. Replenish the fuel in the tank, and reinstall the fuel tank filler cap.

NOTE: Refer to Methanol Fuel Notice in Service Precautions.

8. Reconnect the negative battery cable. If you did not use a memory retention device, reset all devices that lost memory, to the extent possible, when you disconnected the battery.
9. Inspect for leaks.