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.
3. Raise the vehicle.
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 insulator strips (3) and (4), if equipped.
7. Lower fuel tank shield.




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

Fuel Sender Assembly:

10. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring.

INSTALLATION PROCEDURE

Fuel Sender Assembly:

1. Install the new seal ring and reinstall the sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.




3. Raise the tank fully.





IMPORTANT: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Reinstall the fuel tank filler neck (3) to the tank (1).

Tighten
Tighten the clamp (2) 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 runs dry.

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.

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

NOTE: Do not use fuels containing methanol in order to prevent damage and corrosion to the fuel system.

8. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
9. Check for leaks.