Fuel Tank Replacement (Commercial/RV/Cutaway Van)

REMOVAL PROCEDURE





TOOLS REQUIRED
J36608 Fuel Sender Tool

1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle. (This must be done with a frame hoist in order to allow for the rear suspension to hang.)
3. Remove the filler neck hose (3) and the vent hose from the fuel tank (1).
4. Support the fuel tank.




5. Remove the fuel tank bolts (4) and straps (3).
6. Lower the fuel tank (2) and the fuel tank shield.
7. Disconnect the fuel feed and the vapor hoses.
8. Disconnect the electrical connections at the fuel sender assembly.
9. Remove the fuel tank.




10. Use the J 36608 fuel sender tool in order to remove the fuel sender assembly and the seal ring. Discard the old seal ring.
11. Purge the tank if the tank is being repaired.

INSTALLATION PROCEDURE




1. Install a new seal ring.
2. Use the J 36608 fuel sender tool in order to install the fuel sender assembly.
3. Raise the tank slightly.
4. Reconnect the fuel feed and vapor hoses.
5. Reconnect the electrical connector to the fuel sender assembly.




6. Raise the fuel tank (2) fully.
7. Install the fuel tank shield.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank brackets (3) with the insulator strips in place.

NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank runs dry.

Tighten
Tighten the fuel tank bolts (4) to 12 N.m (10 lb ft).




9. Install the fuel filler neck (3) to the fuel tank (1).
10. Replenish the fuel in the fuel tank.
11. Reinstall the fuel tank tiller cap.
12. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all of the devices that lost their memory after the battery was disconnected.
13. Check for any leaks.
13.1. Turn the ignition switch to the ON position for 2 seconds.
13.2. Turn the ignition switch to the OFF position for 10 seconds.
13.3. Again, turn the ignition switch to the ON position.
13.4. Check for any fuel leaks.