Fuel Tank Replacement (Passenger/Cargo Van)

REMOVAL PROCEDURE





TOOLS REQUIRED
J 36608 Fuel Sender Tool

1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle.
3. Remove the off-road shield, if applicable.
4. Loosen the filler neck hose clamp (2) at the fuel tank (1).
5. Disconnect the filler neck hose (3) from the fuel tank.
6. Support the fuel tank.




7. Remove the fuel tank bolts (4), straps (3) and the insulator strips, if applicable.
8. Lower the fuel tank (2) and the fuel tank shield.
9. Disconnect the fuel feed and the vapor hoses.
10. Disconnect the electrical connections at the fuel sender assembly.




11. Use the J 36608 fuel sender tool in order to remove the fuel sender assembly and the seal ring. Discard the old seal ring.
12. Purge the tank if the tank is being repaired.

INSTALLATION PROCEDURE




1. Install a new seal ring.
2. Use the J 36608 fuel sender tool in order to install the fuel sender assembly.
3. Raise the tank slightly.
4. Reconnect the fuel feed and the vapor hoses.
5. Reconnect the electrical connector to the fuel sender assembly.
6. Raise the fuel tank fully.




7. Reinstall the fuel filler neck (3) to the fuel tank (1).

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the clamp (2).

Tighten
Tighten the clamp to 2.5 N.m (25 lb in)




9. Install the fuel tank brackets (3) with the insulator strips in place.

NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank runs dry.

Tighten
Tighten the fuel tank bolts (4) to 45 N.m (33 lb ft).

10. Install the fuel tank off-road shield, if applicable.
11. Replenish the fuel in the fuel tank (2).
12. Reinstall the fuel tank filler cap.
13. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all of the devices that lost their memory after the battery was disconnected.
14. Check for leaks.
14.1. Turn the ignition switch to the ON position for 2 seconds.
14.2. Turn the ignition switch to the OFF position for 10 seconds.
14.3. Again, turn the ignition switch to the ON position.
14.4. Check for any fuel leaks.