Fuel Tank Replacement (Cutaway Van Side Tank)

FUEL TANK REPLACEMENT (CUTAWAY VAN SIDE TANK)

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

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 Vehicle Lifting.
5. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
6. Loosen the fuel fill hose clamp.
7. Disconnect the fuel fill hose from the fuel fill pipe.
8. Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.




9. With the aid of an assistant, support the fuel tank.
10. Remove the attaching bolts (1) from the fuel tank strap.
11. Remove the fuel tank straps (2).
12. Carefully lower the fuel tank.
13. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender.
14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
18. Remove the EVAP pipe from the roll over valves and the retainer clips.
19. Remove the fuel sender assembly from the fuel tank.
20. Remove the fuel fill hose from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel tank insulators (6).
2. Remove the caps from the fuel and EVAP pipes.
3. Install the fuel fill hose to the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

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

4. Install the fuel sender assembly to the fuel tank.
5. Connect the EVAP pipe to the roll-over valves 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. Connect the fuel feed pipe and the fuel return pipe to the fuel sender.
10. Raise the tank fully.
11. Install the fuel tank straps (2).
12. Install the new attaching bolts (1) to the fuel tank strap.

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.

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

13. Connect the rear EVAP pipe (1) to the EVAP canister.




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

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

15. Lower the vehicle.
16. Refill the fuel tank.
17. Tighten the fuel filler cap.
18. Connect the negative battery cable.
19. Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.