Chrysler Caravan/Voyager/Town n Country 1984-1995

Tank Assembly

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REMOVAL & INSTALLATION



All Wheel Drive vehicles, have a fuel tank that is made of plastic. Care should be taken to avoid damaging this tank. The fuel tank in AWD vehicles is mounted at the side of the vehicle instead of the rear.

  1. Release the fuel system pressure. Refer to fuel system pressure release procedure in this section.
  2.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Disconnect battery negative cable.
  2.  
  3. Raise the vehicle and support properly.
  4.  
  5. Remove drain tube rubber cap on left rail and connect a siphon hose to drain tube. Drain fuel into a safe gasoline container.
  6.  
  7. Remove screws supporting filler tube to inner and outer quarter panel.
  8.  
  9. Disconnect wiring and lines from the tank.
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  11. Position a transaxle jack to support the fuel tank and remove the bolts from fuel tank straps.
  12.  
  13. Lower tank slightly, and carefully work filler tube from tank.
  14.  
  15. Lower tank, disconnect vapor separator roll over valve hose and remove the fuel tank and insulator pad from vehicle.
  16.  

To install:
  1. Support the fuel tank with a transaxle jack. Connect the vapor separator roll over valve hose and position insulator pad on fuel tank.
  2.  

Be certain vapor vent hose is clipped to the tank and not pinched between tank and floor pan during installation.

  1. Raise tank into position and carefully work filler tube into tank.
  2.  
  3. Install straps and tighten bolts to 40 ft. lbs. (54 Nm). Remove transaxle jack.
  4.  
  5. Engage lines, drain tube cap and wiring connector, use new hose clamps.
  6.  
  7. Install and tighten filler tube to inner and outer quarter panel. On some models be sure to install the gasket between the filler tube and the inner quarter panel, before installing the mounting screws.
  8.  
  9. Replace cap on drain tube using a new hose clamp.
  10.  
  11. Fill the fuel tank, install the cap, connect battery cable and check operation.
  12.  

 
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