Sprinter 2005-2007

Removal & Installation

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  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove the filler door fasteners, then remove the filler door and gas cap.
  8.  
  9. Remove the filler tube panel fasteners, then remove the filler tube panel.

    Click image to see an enlarged view

    Fig. Remove the two Fuel Filler Door Fasteners (1), and remove the Gas Cap (2) and Fuel Filler Door (3). Remove the 4 Fuel Filler Tube Panel Fasteners (4) and remove the Fuel Filler Tube Panel (2)-Fuel Pump removal

  10.  
  11. Remove the fuel filler tube fastener, located just inside the filler door panel.
  12.  
  13. Remove the tie straps, harness connector and fuel filler grommet.

    Click image to see an enlarged view

    Fig. Remove the tie straps (2), harness connector (1) and Fuel Filler Tube Grommet (3)-3.5L Fuel Tank removal

  14.  
  15. Disconnect the harness connector.
  16.  
  17. Disconnect the Fuel Feed line and Fuel Return line.
  18.  
  19. Remove the front and rear tank straps.
  20.  
  21. Support the fuel tank with a suitable jack.
  22.  
  23. Remove the center fuel tank strap.
  24.  
  25. Disconnect the Evaporative Emission Vent Line (1) from the Fuel Tank (2).
  26.  
  27. Lower the fuel tank from the vehicle.
  28.  

To install:

  1. Raise the fuel tank into position in the vehicle.
  2.  
  3. Reconnect the Evaporative Emission Vent Line (1) to the Fuel Tank (2).
  4.  
  5. Install the Center Fuel Tank Strap and tighten the strap bolt to 41 ft. lbs. (56 Nm).
  6.  
  7. Reconnect the fuel feed and return lines.
  8.  
  9. Reconnect the wiring harness connector.
  10.  
  11. Install the Fuel Filler Tube Grommet, harness connector and tie straps.
  12.  
  13. Install the front and rear Fuel Tank Straps and tighten the strap bolt to 41 ft. lbs. (56 Nm).
  14.  
  15. Install the Fuel Filler Tube and Tube Fastener.
  16.  
  17. Install the Fuel Filler Tube Panel and install the 4 Fuel Filler Tube Panel Fasteners.
  18.  
  19. Install the Fuel Filler Door and the Gas Cap, then install the 2 Fuel Filler Door Fasteners.
  20.  

 
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