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. You must use a frame hoist in order to allow the rear suspension to hang.
4. Remove the filler hose (3) and the 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. Refer to Quick Connect Fittings Service (Metal Collar) or Quick Connect Fittings Service (Plastic Collar).
8. Disconnect the electrical connector at the sender.




9. Remove the fuel tank (2).




10. Use the J 39765 in order to remove the fuel sender and the seal ring. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install the new seal ring, and reinstall the sender using tool J 39765.
2. Raise the tank, and reconnect the electrical connector at the sender.




3. Reconnect the fuel feed hoses and the vapor hoses. Refer to Quick Connect Fittings Service (Metal Collar) or Quick Connect Fittings Service (Plastic Collar).




4. Fully raise the tank (2), and reinstall the tank shield.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: When you remove or replace the fuel tank, never refuse the fuel tank support fasteners. When you install the fuel tank, always use new fasteners.




5. Reinstall the tank straps (3).

Tighten
Tighten the bolts 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: Refer to Methanol Fuel Notice in Service Precautions.

8. Reconnect the negative battery cable.

INSPECTION PROCEDURE

IMPORTANT: The fuel tank tiller 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.