Fuel Tank Replacement Cutaway Van Side Tank
Removal Procedure
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.
- Disconnect the negative battery cable.
- 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
in General Information.
- 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 from the fuel 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 strap .
- Remove the fuel tank straps (2).
- Carefully lower the fuel tank.
- Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the electrical connectors from the fuel sender and the fuel
pressure sensor .
- 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 sender assembly from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Remove the fuel fill hose from the fuel tank.
Installation Procedure
- Install the fuel tank insulators (6).
- Remove the caps from the fuel and EVAP pipes.
Notice: Refer to Fastener Notice in the Preface section.
- Install the fuel fill hose to the fuel tank.
Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).
- Install the fuel sender assembly to the fuel tank. Refer to
Fuel Sender Assembly 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 connectors to the fuel sender and the fuel pressure
sensor .
- Connect the fuel feed pipe and the fuel return pipe to the fuel sender.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Raise the tank fully.
- Install the fuel tank straps (2).
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.
- Install the new attaching bolts (1) to the fuel tank strap .
Tighten
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 hose to the fuel fill
pipe.
Tighten
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.
- Connect the negative battery cable.
- 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 Van
Removal Procedure
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.
- Disconnect the negative battery cable.
- 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
in General Information.
- Loosen the fuel fill hose clamp.
- Disconnect the fuel fill hose from the fuel tank.
- 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.
- Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the chassis fuel feed pipe at the fuel filter. Refer to
Plastic Collar Quick Connect Fitting Service
.
- With the aid of an assistant, support the fuel tank.
- Remove the attaching bolts (4) from the fuel tank strap .
- Remove the fuel tank straps (3).
- Carefully lower the fuel tank.
- Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank and the fuel filter. Refer
to
Fuel Sender Assembly Replacement
.
- Remove the fuel fill hose from the fuel tank.
- Remove the fuel tank from the fuel tank shield.
Installation Procedure
- Install the fuel tank insulators (3).
- Install the fuel tank into the fuel tank shield.
Notice: Refer to Fastener Notice in the Preface section.
- Install the fuel fill hose to the fuel tank.
Tighten
Tighten the fuel fill hose clamp to 2.75 N·m (24 lb in).
- Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to
Fuel Sender Assembly 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 sender and the fuel pressure sensor .
- Raise the tank fully.
- Install the fuel tank straps (3).
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.
- Install the new attaching bolts (4) to the fuel tank strap .
Tighten
Tighten the bolts to 20.5 N·m (15 lb ft).
- Connect the chassis fuel feed pipe to the fuel filter. 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 hose to the fuel fill pipe.
Tighten
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.
- Connect the negative battery cable.
- Inspect for leaks:
18.1. | Turn ON the ignition for 2 seconds. |
18.2. | Turn OFF the ignition for 10 seconds. |
18.3. | Turn ON the ignition. |
18.4. | Inspect for fuel leaks. |
Fuel Tank Replacement Cutaway Van Rear Tank
Removal Procedure
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.
- Disconnect the negative battery cable.
- 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
in General Information.
- Loosen the fuel fill hose clamp (2).
- Disconnect the fuel fill hose from the fuel tank (1).
- 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 strap .
- Remove the fuel tank straps (3).
- Carefully lower the fuel tank.
- Disconnect the electrical connectors from the fuel sender and the fuel
pressure sensor .
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel sender assembly and the rear fuel and EVAP pipes from
the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- Install the fuel tank insulators.
- Install the fuel sender assembly and the rear fuel and EVAP pipes to
the fuel tank. Refer to
Fuel Sender Assembly 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 sender and the fuel pressure
sensor .
- Raise the tank fully.
- 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.
- Install the new attaching bolts (4) to the fuel tank strap .
Tighten
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 hose to the fuel
tank (1).
Tighten
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.
- Connect the negative battery cable.
- Inspect for leaks:
16.1. | Turn ON the ignition for 2 seconds. |
16.2. | Turn OFF the ignition for 10 seconds. |
16.3. | Turn ON the ignition . |
16.4. | Inspect for fuel leaks. |