Compressed Natural Gas Tank Filler Pipe Replacement Passenger/Cargo

Tools Required

J 45878 Combustible Gas Detector

Caution: Natural gas is highly flammable. In order to reduce the risk of fire and personal injury, keep sparks, flames, and smoking materials away from the vehicle while you perform the Compressed Natural Gas (CNG) fuel system service.

Caution: The Compressed Natural Gas (CNG) system operates at pressures up to 24820 kpa (3600 psi). Relieve the CNG fuel system pressure before servicing CNG fuel system components in order to reduce the risk of fire and personal injury.

1. Relieve the CNG fuel system pressure. Refer to Fuel Pressure Relief .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the G/H Van service manual.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the G/H Van service manual.



4. Disconnect the fill line fitting (7) at the fill valve and discard the O-ring.
5. Disconnect the fuel line fitting (10) at the check valve (11) and discard the O-ring.
6. Remove the P-clamp screw (8).
7. Remove the fuel line from the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




1. Connect the fill line fitting (7) to the fill valve using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation.

Tighten
Tighten the fill line fitting to 45 N·m (33 lb ft).

2. Connect the fill line fitting (10) to the check valve (11) using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation.

Tighten
Tighten the fuel line fitting to 45 N·m (33 lb ft).

3. Install the P-clamp mounting screw (8).

Tighten
Tighten the mounting screw to 7 N·m (62 lb in).

4. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the G/H Van service manual.
5. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with the J 45878 or an equivalent leak detector.

Compressed Natural Gas Tank Filler Pipe Replacement Cutaway

Tools Required

J 45878 Combustible Gas Detector

Caution: Natural gas is highly flammable. In order to reduce the risk of fire and personal injury, keep sparks, flames, and smoking materials away from the vehicle while you perform the Compressed Natural Gas (CNG) fuel system service.

Caution: The Compressed Natural Gas (CNG) system operates at pressures up to 24820 kpa (3600 psi). Relieve the CNG fuel system pressure before servicing CNG fuel system components in order to reduce the risk of fire and personal injury.

1. Relieve the CNG fuel system pressure. Refer to Fuel Pressure Relief .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the G/H Van service manual.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the G/H Van service manual.



4. Disconnect the fill line fitting (1) at the fill valve and discard the O-ring.
5. Disconnect the fuel line fitting (4) at the check valve (5) and discard the O-ring.
6. Remove the P-clamp bolt (2).
7. Remove the fuel line from the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




1. Connect the fill line fitting (1) to the fill valve using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation.

Tighten
Tighten the fill line fitting to 45 N·m (33 lb ft).

2. Connect the fill line fitting (4) to the check valve (5) using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation.

Tighten
Tighten the fuel line fitting to 45 N·m (33 lb ft).

3. Install the P-clamp mounting bolt (8), washer and nut.

Tighten
Tighten the mounting bolt to 25 N·m (18 lb in).

4. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the G/H Van service manual.
5. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with the J 45878 or an equivalent leak detector.