Fuel Tank Removal and Installation (Passenger/Cargo Van)

Fuel Tank Replacement (Passenger/Cargo Van)

Removal Procedure






Caution: Refer to Battery Disconnect Caution.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
3. Drain the fuel tank. Refer to Fuel Tank Draining.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Loosen the fuel fill hose clamp.
6. On cargo van, disconnect the fuel fill hose from the fuel tank.




7. On passenger van, disconnect the fuel fill hose from the fuel tank.




8. On all models, 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.
9. Disconnect the rear fuel return pipe (1) at the chassis fuel return pipe.
10. Disconnect the rear fuel feed pipe (2) at the chassis fuel feed pipe.




11. With the aid of an assistant, support the fuel tank.
12. Remove and discard the attaching bolts (1) from the fuel tank strap.
13. Remove the fuel tank straps (2).
14. Carefully lower the fuel tank.
15. Disconnect the fuel sender and the fuel pump electrical connectors.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.




18. Remove the fuel sender assembly (1) and the fuel pipes from the fuel tank.
19. Remove the evaporative emission (EVAP) hoses from the fuel tank and EVAP canister (2).
20. Remove two tiedown straps from the EVAP canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
21. Remove the fuel fill hose from the fuel tank.
22. Remove the fuel tank from the fuel tank shield (3).

Installation Procedure




1. Install the fuel tank into the fuel tank shield (3).

Notice: Refer to Fastener Notice.

2. Install the fuel fill hose to the fuel tank.

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

3. Place the EVAP canister in position on the EVAP canister bracket, then install two new tiedown straps.
4. Install the EVAP hoses to the fuel tank and EVAP canister (2).
5. Install the fuel sender assembly (1) and the fuel pipes to the fuel tank.




6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the electrical connectors to the fuel sender and fuel pump.
9. Raise the tank fully.
10. 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.

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

Tighten the bolts to 20.5 N.m (15 lb ft).




12. Connect the chassis fuel feed pipe to the rear fuel feed pipe (2).
13. Connect the rear fuel return pipe (1) to the chassis fuel return pipe.




14. On passenger van, connect the fuel fill hose to the fuel tank.




15. On cargo van, connect the fuel fill hose to the fuel tank.

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

16. On all models, lower the vehicle.
17. Refill the fuel tank.
18. Tighten the fuel filler cap.
19. Connect the negative battery cable.
20. Inspect for leaks:

1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.