TownAndCountry 2008

Removal & Installation

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CAUTION
The fuel system is under constant pressure even with engine OFF. Before servicing any part of the fuel system, the pressure must be released.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel cap.
  4.  
  5. Release the fuel system pressure. Refer to Relieving Fuel System Pressure.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the hose clamp and remove the fuel fill hose from the fuel tank.
  10.  
  11. Disconnect the fuel pump electrical connector from the body harness connector.
  12.  
  13. Disconnect the fuel line quick connect fittings (1) and the evaporator hose (2).

    Click image to see an enlarged view

    Fig. Disconnect the fuel line quick connect fitting (1) and the evaporator hose quick connect fitting (2)

  14.  
  15. Disconnect the electrical connector (1) from the Evaporative System Integrity Monitor (ESIM) switch (2).
  16.  
  17. Disconnect the fuel fill vapor hose from the fuel tank control valve hose.
  18.  
  19. Disconnect the fuel fill vapor hose (3) from the ESIM switch (2).
    WARNING
    Support the fuel tank with a transmission jack, or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or the fuel tank to fall from the jack assembly.



    Click image to see an enlarged view

    Fig. Location of Evaporative System Integrity Monitor (ESIM) switch

  20.  
  21. Remove the fuel tank strap bolts (3) and the straps (2).
  22.  
  23. Remove the vapor canister bracket bolt (1).

    Click image to see an enlarged view

    Fig. Loosen the fuel tank strap bolts and remove the vapor canister bracket bolt

  24.  
  25. Lower the fuel tank.
  26.  
  27. Disconnect the evaporator quick connector (1) from the vapor line.
  28.  
  29. Disconnect the evaporator quick connector (3) from the fuel tank control valve.
  30.  
  31. Remove the vapor canister filter (2).

    Click image to see an enlarged view

    Fig. Evaporative Emissions (EVAP) canister location

  32.  
  33. Remove the fuel pump module. Refer to Fuel Pump Module, removal & installation.
  34.  
  35. Remove all the fuel and vapor lines from the fuel tank.
  36.  
  37. Transfer the fuel into an approved fuel storage container.
  38.  

To install:

  1. Install all the fuel and vapor lines to the fuel tank.
  2.  
  3. Install the fuel pump module Refer to Fuel Pump Module, removal & installation.
  4.  
  5. Install the vapor canister filter (2).
  6.  
  7. Connect the evaporator quick connector (3) to the fuel tank control valve.
  8.  
  9. Connect the evaporator quick connector (1) to the vapor line.
  10.  
  11. Position the fuel tank onto a transmission jack, or equivalent and raise the fuel tank into vehicle position.
  12.  
  13. Install the vapor canister bracket bolt (1). Tighten to 41 ft. lbs. (55 Nm).
  14.  
  15. Install the straps (2) and the fuel tank strap bolts (3). Tighten to 41 ft. lbs. (55 Nm).
  16.  
  17. Connect the fuel fill vapor hose (3) to the ESIM switch (2).
  18.  
  19. Connect the fuel fill vapor hose to the fuel tank control valve hose.
  20.  
  21. Connect the electrical connector (1) to the ESIM switch (2).
  22.  
  23. Connect the fuel line quick connect fittings (1) and the evaporator hose (2).
  24.  
  25. Connect the body harness connector.
  26.  
  27. Install the fuel fill hose and hose clamp to the fuel tank. Tighten the hose clamp (1) to 21 ft. lbs. (28 Nm).
  28.  
  29. Fill the fuel tank and install the fuel cap.
  30.  
  31. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  32.  

 
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