Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 17
Fig.
3
Fuel
T
ank
Assembly—Front
Wheel
Drive
.
FUEL SYSTEM
14 - 15
(5) Raise vehicle. Disconnect fuel pump/level unit
electrical connector.
(6) Disconnect fuel line quick connect fittings from
the tank. Refer to Tube/Fitting Disassembly in the Fuel
Delivery section of this Group.
(7) Use a transmission jack to support the fuel tank.
Remove the bolts from the fuel tank straps.
(8) Lower tank slightly. Carefully remove filler tube
from tank.
(9) Lower
the
fuel
tank.
Disconnect
pressure
relief/rollover valve hose. Remove clamp and remove
fuel filler tube vent hose. Remove the fuel tank from
the vehicle.
FUEL TANK INSTALLATION—FRONT WHEEL
DRIVE
(1) Position fuel tank on transmission jack. Connect
pressure relief/rollover valve hose. Connect fuel filler
tube vent hose and replace clamp.
(2) Raise tank into position and carefully work filler
tube into tank. A light coating of transmission fluid on
the tube end may be used to aid assembly.
(3) Tighten strap bolts to 54.2 N
Im (40 ft. lbs.)
torque. Remove transmission jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(4) Connect fuel pump/level unit electrical connector.
(5) Lubricate the metal tubes on the fuel pump with
clean 30 weight engine oil. Install the quick connect
fuel fittings. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(6) Attach filler tube to filler neck opening in quarter
panel. Tighten quarter panel screws to 1.9 N
Im (17 in.
lbs.) torque. On affected models be sure to install the
gasket between the filler tube and the inner quarter
panel, before installing the mounting screws.
(7) Using a new clamp, install cap on fuel tank drain
tube.
(8) Fill fuel tank, replace cap, and connect battery
ground cable.
CAUTION: When using the ASD Fuel System Test, the
ASD relay and fuel pump relay remain energized for 7
minutes or until the test is stopped, or until the
ignition switch is turned to the Off position.
(9) Use the DRB II tester ASD Fuel System Test to
pressurize the fuel system. Check for leaks.
FUEL TANK—ALL WHEEL DRIVE
DRAINING FUEL TANK—ALL WHEEL DRIVE
(1) Perform the Fuel System Pressure Release pro-
cedure.
(2) Disconnect battery ground cable.
(3) Raise vehicle on hoist.
(4) Remove rubber cap from fuel tank drain tube.
The cap is located above the rear differential torque
tube, on the inboard side of the fuel tank (Fig. 4).
Connect a portable holding tank to the drain tube.
(5) Completely drain fuel tank into holding tank or a
properly labeled gasoline safety container.
FUEL TANK REMOVAL—ALL WHEEL DRIVE
(1) Perform the Fuel System Pressure Release Pro-
cedure. Refer to Fuel System Pressure Release in this
section.
(2) Disconnect battery ground cable.
(4) Remove fuel filler cap.
(3) Drain
fuel
tank.
Refer
to
Draining
Fuel
Tank—All Wheel Drive in this section.
(5) Remove screws that hold filler tube to opening in
quarter panel.
(6) Raise vehicle on hoist.
(7) Remove fasteners holding the park brake cable
support bracket assembly in place (Fig. 5).
Fig. 4 Fuel Tank Drain Cap
Fig. 5 Brake Cable Support Bracket—All Wheel
Drive
14 - 16
FUEL SYSTEM
.
(8) Use a transmission jack to support the fuel tank.
Remove the bolts from the fuel tank straps (Fig. 6).
(9) Loosen fuel filler tube vent hose clamp and
remove hose from tube.
(10) Lower tank slightly.
(11) Clean the quick connectors to remove any dirt.
(Use air pressure or an appropriate cleaning agent).
Disconnect fuel supply and return hoses from the
chassis fuel tubes by pushing in on the black plastic
release ring and pulling on the connector. Refer to
Tube/Fitting disassembly in the Fuel Delivery Section
of this group.
(12) Disconnect the fuel vent hose. Plug hoses to
prevent contamination.
(13) Remove electrical connector from the fuel pump
module (Fig. 7).
(14) Pull fuel filler vent hose through the frame rail.
(15) Lower the fuel tank and remove the fuel filler
tube from the fuel tank.
FUEL TANK INSTALLATION—ALL WHEEL
DRIVE
(1) Position fuel tank on transmission jack. Insert
fuel filler tube into opening in tank.
(2) Raise fuel tank while inserting fuel filler vent
hose through hole in frame rail.
(3) Ensure that the black release rings of the supply
and return fuel hose quick connect fittings are in the
OUT position. The release ring should be loose and free
floating.
(4) Lubricate the ends of the chassis fuel tubes
(supply and return only) with clean 30 weight engine
oil.
CAUTION: When making connections with quick con-
nect fittings, always pull back on the fitting to ensure
complete engagement. If the fitting will not fully
connect, make sure the black release ring is not
jammed into the metal casing of the fitting. If the
fitting fails, replace it with a new one of the correct
size.
(5) Couple quick connect fittings of the fuel supply
and return hoses to the chassis fuel tubes. Refer to
Tube/Fitting Assembly in the Fuel Delivery Section of
this Group.
(6) Connect the fuel tank vent hose to the chassis
fuel tube.
(7) Connect fuel pump electrical connector to the
fuel pump module.
(8) Install drain tube cap.
(9) Raise fuel tank into position. Carefully twist the
filler tube and fuel filler vent tube into position.
CAUTION: Be sure straps are not twisted or bent
before or after tightening strap nuts.
(10) Install fuel tank support straps. Tighten fasten-
ers to 54.2 N
Im (40 ft.lbs.) torque. Remove the trans-
mission jack.
(11) Connect fuel filler vent hose and tighten hose
clamp.
(12) Install park brake cable support bracket.
Tighten the fasteners to 22.6 N
Im (200 in. lbs.) torque.
(13) Lower vehicle.
(14) Attach filler tube to filler neck opening in quar-
ter panel. Tighten quarter panel screws to 1.9 N
Im (17
inch-pounds) torque. On affected models, install gasket
between the filler tube and the inner quarter panel
before installing the mounting screws.
Fig. 6 All Wheel Drive Fuel Tank
Fig. 7 Fuel Pump Module—All Wheel Drive
.
FUEL SYSTEM
14 - 17
(15) Fill fuel tank, replace cap, connect battery
ground cable and check system operation.
CAUTION: When using the ASD Fuel System Test, the
ASD relay and fuel pump relay remain energized for 7
minutes or until the test is stopped, or until the
ignition switch is turned to the Off position.
(16) Pressurize the system using the DRB II. With
ignition key in the Run position, use ASD Fuel System
Test. This will activate the fuel pump and pressurize
the system. Check system for leaks.
FUEL PUMP/LEVEL UNIT—FRONT WHEEL DRIVE
Refer to the Fuel Delivery Section in this Group for
fuel pump/level unit service.
FUEL PUMP MODULE—ALL WHEEL DRIVE
Refer to the Fuel Delivery Section in this Group for
fuel pump module service.
FUEL TANK PRESSURE RELIEF/ROLLOVER
VALVE—FRONT WHEEL DRIVE
REMOVAL
(1) Remove fuel tank. Refer to fuel tank removal.
(2) Wedge the blade of a screwdriver between the
rubber grommet and the fuel tank where the support
rib is located. Do not wedge between the valve and
the grommet, this could damage the valve during
removal.
(3) Use a second screwdriver as a support to pry the
valve and grommet assembly from the tank (Fig. 8).
(4) Place the valve upright on a flat surface to
remove the grommet. Push down on the grommet and
peel it off the valve.
INSTALLATION
(1) Position the rubber grommet in the fuel tank by
rolling it around the curled lip of the tank.
Only use power steering fluid to lubricate the
grommet.
(2) Lubricate the grommet with power steering fluid.
(3) Push the valve downward into the grommet.
Twist valve until properly positioned (Fig. 9).
(4) Install fuel tank. Refer to fuel tank installation
in this section.
Fig. 9 Installing Pressure Relief/Rollover Valve
Fig. 8 Removing Pressure Relief/Rollover
Valve—Front Wheel Drive.
14 - 18
FUEL SYSTEM
.
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