Chrysler Caravan/Voyager/Town and Country 1996-1999

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel filler cap.
  4.  
  5. Properly relieve the fuel system pressure, as outlined earlier in this section.
  6.  
  7. Insert a fuel syphon hose into the fuel filler neck and push it into the fuel tank.
  8.  
  9. Drain the fuel tank dry into a proper holding tank or a properly labeled gasoline safety container.
  10.  
  11. Raise and safely support the vehicle.
  12.  



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Fig. Fig. 1: Disconnect the fuel tank filler and vent hoses

  1. Disconnect both the fuel filler and vent rubber hoses at the fuel tank.
  2.  
  3. Disconnect the supply lines from the: fuel pump module located on top of the fuel tank (1996), or the steel supply line (1997-99).
  4.  



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Fig. Fig. 2: Disengage the fuel pump connector ...



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Fig. Fig. 3: ... then disconnect the fuel line quick connect fittings



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Fig. Fig. 4: Fuel pump module connector retainer and lock

  1. Slide the fuel pump module electrical connector lock to the unlock position, then push down on the retainer and pull the connector off of the module.
  2.  
  3. Place a transmission jack, or equivalent support fixture, under the fuel tank.
  4.  
  5. With the tank supported by a transmission jack, or equivalent, remove the bolts and fuel tank mounting straps.
  6.  
  7. Lower the fuel tank slightly. Carefully remove the filler hose from the tank.
  8.  
  9. Lower the fuel tank. Disconnect the pressure relief/rollover valve hose at the front of the tank. Remove clamp, then remove the fuel filler tube vent hose. Remove the tank from the vehicle.
  10.  



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Fig. Fig. 5: With the tank supported by a transmission jack, or equivalent, remove the bolts and fuel tank mounting straps



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Fig. Fig. 6: Fuel tank assembly

To install:
  1. Position the fuel tank onto the transmission jack. Connect the pressure relief/rollover valve hose. Connect the fuel filler tube vent hose and replace the clamp.
  2.  
  3. Raise the tank into position and carefully work filler tube into the fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
  4.  
  5. Feed the filler vent line through the frame rail, being very careful not to cross the lines.
  6.  
  7. Tighten the fuel tank strap bolts to 40 ft. lbs. (54 Nm). Check to make sure that the tank straps are not twisted or bent. Remove the transmission jack.
  8.  
  9. Attach the fuel pump/module electrical connector and place the retainer in the locked position.
  10.  
  11. Lubricate the fuel line with clean 30W engine oil, then install the quick connect fitting. If necessary, refer to the quick-connect fitting information earlier in this section.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Fill the fuel tank, install the filler cap, then connect the negative battery cable.
  16.  


CAUTION
When performing the ASD fuel system test, the ASD relay will remain energized for either 7 minutes, until the test is completed, or until the ignition switch is turned to the OFF position.

  1. Pressurize the fuel system using the Chrysler DRB, or equivalent scan tool, to perform the ASD fuel system test. Check the fuel system for leaks.
  2.  

 
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