Fuel Tank Replacement Passenger/Cargo Van

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

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.

3. Drain the fuel tank. Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

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



7. Clean all fuel pipe connections and 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 Plastic Collar Quick Connect Fitting Service .
9. Disconnect the chassis fuel feed pipe (7) at the fuel filter (6). Refer to Plastic Collar Quick Connect Fitting Service .
10. Disconnect the chassis evaporative emission (EVAP) purge pipe (5) at the EVAP canister.
11. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.



12. With the aid of an assistant, support the fuel tank.
13. Remove the fuel tank strap attaching bolts (4).
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.

1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.
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. Refer to Fuel Sender Assembly Replacement .
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 fuel sender and the fuel pressure sensor electrical connectors.
9. Raise the tank fully.
10. Install the fuel tank straps (3).

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.

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 fuel tank strap attaching bolts (4).

Tighten
Tighten the fuel tank strap attaching 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 Plastic Collar Quick Connect Fitting Service .
15. Connect the rear fuel return pipe (2) to the chassis fuel return pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .



16. Connect the fuel fill hose (6) to the fuel fill pipe (4).

Tighten
Tighten the fuel fill hose clamp (5) 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 the ignition ON for 2 seconds.

21.2.

Turn the ignition OFF for 10 seconds.

21.3.

Turn the ignition ON.

21.4.

Inspect for fuel leaks.

Fuel Tank Replacement Cutaway Van Side Tank

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
6. Loosen the fuel fill hose clamp (3).
7. Disconnect the fuel fill hose (6) from the fuel fill pipe (5).



8. Disconnect the rear evaporative emission (EVAP) pipe (1) at the EVAP canister.



9. With the aid of an assistant, support the fuel tank.
10. Remove the fuel tank strap attaching bolts (2).
11. Remove the fuel tank straps (1).
12. Carefully lower the fuel tank.
13. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
14. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
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. Refer to Fuel Sender Assembly Replacement .
20. Remove the fuel fill hose from the fuel tank.

1. Install the fuel tank insulators.
2. Remove the caps from the fuel and EVAP pipes.

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.

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 to the fuel tank. Refer to Fuel Sender Assembly Replacement .
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 fuel sender and the fuel pressure sensor electrical connectors.
9. Connect the fuel feed pipe and the fuel return pipe to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
10. Raise the tank fully.
11. Install the fuel tank straps (1).

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.

12. Install the new fuel tank strap attaching bolts (2).

Tighten
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 (6) to the fuel fill pipe (5).

Tighten
Tighten the fuel fill hose clamp (3) 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.

19.1.

Turn the ignition ON for 2 seconds.

19.2.

Turn the ignition OFF for 10 seconds.

19.3.

Turn the ignition ON.

19.4.

Inspect for fuel leaks.

Fuel Tank Replacement Cutaway Van Rear Tank

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

4. 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 in General Information.
5. Loosen the fuel fill hose clamp (2).
6. Disconnect the fuel fill hose from the fuel tank (1).



7. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
8. Disconnect the rear fuel and evaporative emission (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .
9. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.



10. With the aid of an assistant, support the fuel tank.
11. Remove the fuel tank strap attaching bolts (4).
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank. Refer to Fuel Sender Assembly Replacement .

1. Install the fuel tank insulators.
2. Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank. Refer to Fuel Sender Assembly Replacement .



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

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.

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.

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

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




9. Remove the caps from the fuel and EVAP pipes.
10. Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .



11. Connect the fuel fill hose to the fuel tank (1).

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

12. Lower the vehicle.
13. Refill the fuel tank.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for leaks.

16.1.

Turn the ignition ON for 2 seconds.

16.2.

Turn the ignition OFF for 10 seconds.

16.3.

Turn the ignition ON.

16.4.

Inspect for fuel leaks.