Fuel Tank Replacement Cutaway Van Rear Tank
Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Drain the fuel tank. Refer to
Fuel Tank Draining.
- Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to
Lifting and Jacking the Vehicle.
- Disconnect the fuel fill hose (1) from the fuel fill tube.
- Disconnect the fuel fill vent hose (2) from the fuel fill tube.
- Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
- Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to
Plastic Collar Quick Connect Fitting Service.
- Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
- With the aid of an assistant, support the fuel tank.
- Remove the attaching bolts (4) from the fuel tank straps. Discard attaching bolts.
- Remove the fuel tank straps (3) and two fuel tank strap insulators.
- Carefully lower the fuel tank.
- Disconnect the electrical connectors from the fuel tank module and the fuel pressure sensor.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel fill hose and fuel fill vent hose from the fuel tank.
- Remove the fuel tank module and the rear fuel and EVAP pipes from the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
Installation Procedure
- Install the fuel tank insulators.
- Install the fuel tank module and the rear fuel and EVAP pipes to the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Install the fuel fill hose and fuel fill vent hose to the fuel tank.
- With the aid of an assistant, position and support the fuel tank.
- Raise the fuel tank slightly.
- Connect the electrical connectors to the fuel tank module and the fuel pressure sensor.
- Raise the tank fully.
- Install the fuel tank straps (3).
Caution: Refer to Fastener Caution in the Preface section.
Note: 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.
- Install the new attaching bolts (4) to the fuel tank straps and tighten the bolts to
20.5 N·m (15 lb ft).
- Remove the caps from the fuel and EVAP pipes.
- Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the fuel fill vent hose (2) to the full pipe.
- Connect the fuel fill hose to the fuel tank (1) and tighten the fuel fill hose clamp (2) to
2.75 N·m (24 lb in).
- Lower the vehicle.
- Refill the fuel tank.
- Tighten the fuel filler cap.
- Inspect for leaks:
17.1. | Turn ON the ignition for 2 seconds. |
17.2. | Turn OFF the ignition for 10 seconds. |
17.3. | Turn ON the ignition. |
17.4. | Inspect for fuel leaks. |
Fuel Tank Replacement Cutaway Van Side Tank
Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Drain the fuel tank. Refer to
Fuel Tank Draining.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
- Loosen the fuel fill hose clamp.
- Disconnect the fuel fill hose (1) from the fuel fill pipe.
- Disconnect the fuel fill vent hose (2) from the fill pipe.
- Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.
- With the aid of an assistant, support the fuel tank.
- Remove the attaching bolts (1) from the fuel tank straps. Discard attaching bolts.
- Remove the fuel tank straps (2).
- Carefully lower the fuel tank.
- Disconnect the fuel feed pipe and the fuel return pipe at the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the electrical connector from the fuel tank module.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
- Remove the EVAP pipe from the roll over valves and the retainer clips.
- Remove the fuel tank module from the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Remove the fuel fill hose from the fuel tank.
Installation Procedure
- Install the fuel tank into the fuel tank shield (3)..
- Remove the caps from the fuel and EVAP pipes.
Caution: Refer to Fastener Caution in the Preface section.
- Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to
2.75 N·m (24 lb in).
- Install the fuel tank module to the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Connect the EVAP pipe to the roll-over valves and the retainer clips.
- With the aid of an assistant, position and support the fuel tank.
- Raise the fuel tank slightly.
- Connect the electrical connector to the fuel tank module.
- Connect the fuel feed pipe and the fuel return pipe to the fuel tank module. Refer to
Plastic Collar Quick Connect Fitting Service.
- Raise the tank fully.
- Install the fuel tank straps (2).
Note: 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.
- Install the new attaching bolts (1) to the fuel tank straps. Tighten the fuel tank strap attaching bolts to
20.5 N·m (15 lb ft).
- Connect the rear EVAP pipe (1) to the EVAP canister.
- Connect the fuel fill vent hose (2) to the fill pipe.
- Connect the fuel fill hose (1) to the fuel fill pipe and tighten the fuel fill hose clamp to
2.75 N·m (24 lb in).
- Lower the vehicle.
- Refill the fuel tank.
- Tighten the fuel filler cap.
- Inspect for leaks:
19.1. | Turn ON the ignition for 2 seconds. |
19.2. | Turn OFF the ignition for 10 seconds. |
19.3. | Turn ON the ignition. |
19.4. | Inspect for fuel leaks. |
Fuel Tank Replacement Passenger/Cargo
Removal Procedure
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Drain the fuel tank. Refer to
Fuel Tank Draining.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle.
- 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.
- Loosen the fuel fill hose clamp.
- Disconnect the fuel fill hose (1) from the filler tube.
- Disconnect the fuel fill vent hose (2) from the filler tube.
- Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- With the aid of an assistant, support the fuel tank.
- Remove and discard the attaching bolts (1) from the fuel tank strap.
- Remove the fuel tank straps (2).
- Carefully lower the fuel tank.
- Disconnect the fuel tank module and the fuel pump electrical connectors.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel tank module (1) and the fuel pipes from the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
- Remove the evaporative emission (EVAP) hoses from the fuel tank.
- On models with EVAP canister mounted to fuel tank, remove two tiedown straps from the (EVAP) canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
- On all models, remove the fuel fill hose from the fuel tank.
- Remove the fuel tank from the fuel tank shield (3).
Installation Procedure
- Install the fuel tank into the fuel tank shield (3).
Caution: Refer to Fastener Caution in the Preface section.
- Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to
2.75 N·m (24 lb in).
- On models with EVAP canister mounted to fuel tank, place the (EVAP) canister in position on the (EVAP) canister bracket, then install two new tiedown straps.
- On all models, install the (EVAP) hoses to the fuel tank.
- Install the fuel tank module (1) and the fuel pipes to the fuel tank. Refer to
Fuel Tank Fuel Pump Module Replacement.
- With the aid of an assistant, position and support the fuel tank.
- Raise the fuel tank slightly.
- Connect the electrical connectors to the fuel tank module and fuel pump.
- Raise the tank fully.
- Install the fuel tank straps (2).
Note: 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.
- Install the new attaching bolts (1) to the fuel tank strap and tighten the bolts to
20.5 N·m (15 lb ft).
- Connect the chassis fuel feed pipe to the rear fuel feed pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to
Plastic Collar Quick Connect Fitting Service.
- Connect the fuel fill vent hose (2) to the filler tube.
- Connect the fuel fill hose (1) to the fuel tank and tighten the fuel fill hose clamp to
2.75 N·m (24 lb in).
- Lower the vehicle.
- Refill the fuel tank.
- Tighten the fuel filler cap.
- Inspect for leaks:
19.1. | Turn ON the ignition for 2 seconds. |
19.2. | Turn OFF the ignition for 10 seconds. |
19.3. | Turn ON the ignition. |
19.4. | Inspect for fuel leaks. |