Fuel Tank Replacement (Commercial/RV/Cutaway Van)

REMOVAL PROCEDURE

Tools Required
J 36608 Fuel Sender Tool




1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

2. Raise the vehicle. This must be done with a frame hoist to allow 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. Refer to Quick Connect Fittings Service (Plastic Collar).
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. Refer to Quick Connect Fittings Service (Plastic Collar).
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.
^ 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 is empty.

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

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. Lower the vehicle.
11. Replenish the fuel in the fuel tank.
12. Reinstall the fuel tank filler cap.
13. 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.
14. Inspect for leaks with the following procedure:
14.1. Turn ON the ignition for 2 seconds.
14.2. Turn OFF the ignition for 10 seconds.
14.3. Again, turn ON the ignition.
14.4. Inspect for any fuel leaks.