Fuel Tank Replacement (Passenger/Cargo Van)

REMOVAL PROCEDURE




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.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Loosen the fuel fill hose clamp (2).
6. Disconnect the fuel till hose from the fuel fill pipe.




7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
8. Disconnect the rear fuel return pipe (2) at the chassis fuel return pipe (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar).
9. Disconnect the chassis fuel feed pipe (7) at the fuel filter (6). Refer to Quick Connect Fitting(s) Service (Plastic Collar).
10. Disconnect the chassis EVAP purge pipe (5) at the EVAP canister.
11. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.




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




19. Disconnect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.
20. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement
21. Remove the fuel fill hose from the fuel tank.
22. Remove the fuel tank from the fuel tank shield.

INSTALLATION PROCEDURE




1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the fuel fill hose to the fuel tank.

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

4. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter.
5. Connect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.




6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
9. Raise the tank fully.
10. Install the fuel tank straps (3).

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.

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

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




12. Remove the caps from the fuel and EVAP pipes.
13. Connect the chassis EVAP purge pipe (5) to the EVAP canister.
14. Connect the chassis fuel feed pipe (7) to the fuel filter (6). Refer to Quick Connect Fitting(s) Service (Plastic Collar).
15. Connect the rear fuel return pipe (2) to the chassis fuel return pipe (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar).




16. Connect the fuel fill hose to the fuel fill pipe.

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

17. Lower the vehicle.
18. Refill the fuel tank.
19. Tighten the fuel filler cap.
20. Connect the negative battery cable.
21. Inspect for leaks:
21.1. Turn ON the ignition for 2 seconds.
21.2. Turn OFF the ignition for 10 seconds.
21.3. Turn ON the ignition.
21.4. Inspect for fuel leaks.
22. Install the engine cover.