Fuel Tank Replacement (Commercial/RV/Cutaway Van)
REMOVAL PROCEDURE
TOOLS REQUIRED
J 39765 Fuel Sender Locknut Wrench
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)
4. Remove the filler hose (3) and vent hose from the fuel tank (1).
5. Support the fuel tank and remove the fuel tank straps (3).
6. Lower the fuel tank shield and the fuel tank (2).
7. Disconnect the fuel feed and vapor hoses.
8. Disconnect the electrical connector at the sender.
9. Remove the fuel tank (2).
Fuel Sender Assembly:
10. Remove the fuel sender and the seal ring, using tool J 39765. Discard the old seal ring.
INSTALLATION PROCEDURE
Fuel Sender Assembly:
1. Install the new seal ring and reinstall the sender using tool J39765.
2. Raise the tank and reconnect the electrical connector at the sender.
3. Reconnect the fuel feed and vapor hoses.
4. Raise the tank (2) fully and reinstall the tank shield.
IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Reinstall the tank straps (3).
Tighten
Tighten the bolts (4) to 20 N.m (15 lb ft).
6. Reinstall the filler hose (3) and the vent hose to the tank.
7. Replenish the fuel. Reinstall the fuel tank filler cap.
NOTE: Do not use fuels containing methanol in order to prevent damage and corrosion to the fuel system.
8. Reconnect the negative battery cable.
INSPECTION PROCEDURE
IMPORTANT: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.
Turn the ignition switch ON for two seconds then turn the switch OFF for ten seconds. Again turn the ignition switch ON and check for fuel leaks.