Replacing Fuel Tank in '02 Caravan
The engine light has been coming off and on over last 8 months since we had the fuel pump replaced in our '02 Caravan - we took it to the shop today and were told that there is a valve that is in the top of the tank that is leaking fumes and this is causing the sensor to go off - we were told that they tried to seal around the valve but were unable to and that we need a new tank and it will cost us about $660.00 - does this sound right and if the tank does need to be replaced how difficult a job is it? I do my own brakes and general main.
REMOVAL
Remove fuel filler cap and perform Fuel System Pressure Release procedure (Fuel Tank).
Disconnect negative cable from battery.
Insert fuel siphon hose into fuel filler neck and push it into the tank.
Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container.
Raise vehicle on hoist and support.
Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
Lower tank slightly.
Disconnect the fuel filler vent tube. Squeeze tabs and pull apart (FUEL FILLER AND VENT TUBE).
Disconnect the fuel fill hose at the fuel tank filler metal tube NOT AT THE FUEL TANK(FUEL FILLER AND VENT TUBE).
Disconnect fuel line and vapor line at the front of the fuel tank. The fuel pump module electrical connector has a retainer that locks it in place.
Slide fuel pump module electrical connector lock to unlock (Fuel Line Retainers and Pump Connector Lock).
Push down on connector retainer (Pump Module Connector Retainer and Lock) and pull connector off module.
Lower tank from vehicle. Remove fuel filler vent tube from frame (VENT HOSE).
Remove fuel filler cap and perform Fuel System Pressure Release procedure (Fuel Tank).
Disconnect negative cable from battery.
Insert fuel siphon hose into fuel filler neck and push it into the tank.
Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container.
Raise vehicle on hoist and support.
Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
Lower tank slightly.
Disconnect the fuel filler vent tube. Squeeze tabs and pull apart (FUEL FILLER AND VENT TUBE).
Disconnect the fuel fill hose at the fuel tank filler metal tube NOT AT THE FUEL TANK(FUEL FILLER AND VENT TUBE).
Disconnect fuel line and vapor line at the front of the fuel tank. The fuel pump module electrical connector has a retainer that locks it in place.
Slide fuel pump module electrical connector lock to unlock (Fuel Line Retainers and Pump Connector Lock).
Push down on connector retainer (Pump Module Connector Retainer and Lock) and pull connector off module.
Lower tank from vehicle. Remove fuel filler vent tube from frame (VENT HOSE).



