Fuel Tank Replacement Passenger/Cargo Van

1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
2. Raise the vehicle.



3. Remove the fuel tank off-road shield, if equipped.



4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.
6. Lower fuel tank shield.



7. Lower the fuel tank. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.



8. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring. Purge the tank, if the tank is being repaired.

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.

4. Reinstall the fuel tank filler neck to the tank.

Tighten
Tighten the clamp to 2.75 N·m (24.3 lb in).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.





Notice: 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.

5. Install the fuel tank brackets with insulator strips in place. Tighten the strap nuts to 45 N·m (33 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.

Notice: 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.

Fuel Tank Replacement Commercial/RV Cutaway

1. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure .
2. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)



3. Remove the filler hose and vent hose from the fuel tank.



4. Support the fuel tank and remove the fuel tank straps.



5. Lower the fuel tank shield and the fuel tank.



6. Disconnect the fuel feed and vapor hoses. Refer to Fuel Hose and Pipes (Service Quick Connect Fittings) .
7. Disconnect the electrical connector at the sender.



8. Remove the fuel tank.



9. Remove the fuel sender and the seal ring, using tool J 39765 . Discard the old seal ring. Purge the tank, if the tank is being repaired.

1. Install the new seal ring and reinstall the sender using tool J 39765 .
2. Raise the tank and reconnect the electrical connector at the sender.



3. Reconnect the fuel feed and vapor hoses. Refer to Fuel Hose and Pipes (Service Quick Connect Fittings) .



4. Raise the tank fully and reinstall the tank shield.



5. Reinstall the tank straps.

Tighten
Tighten the bolts to 12 N·m (10 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




6. Reinstall the filler hose and the vent hose to the tank.
7. Replenish the fuel. Reinstall the fuel tank filler cap.

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

8. Reconnect the negative battery cable.

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

Turn the ignition switch ON for two seconds then turn the switch OFF for ten seconds. Again turn the ignition switch ON and check for fuel leaks.