Fuel Tank Removal/Installation Procedure

FUEL TANK REMOVAL/INSTALLATION PROCEDURE

REMOVAL
1. Disconnect negative battery cable at battery.
2. Remove fuel tank filler cap before disconnecting any fuel or vent lines. The tank could be under a small pressure.
3. Drain fuel tank. Refer to Draining Fuel Tank.

WARNING: WRAP SHOP TOWELS AROUND FUEL FILLER HOSES TO ABSORB ANY GASOLINE THAT MIGHT SPILL.

Fig 39 Fuel Fill And Vent Hose Connections -- Typical:

4. Raise vehicle on hoist and disconnect filler vent hose and filler hose. Remove the vent hoses from hose routing bracket attached to the top of the frame rail.

5. Place a transmission jack under the center of the fuel tank and apply slight pressure.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

6. Disconnect the retaining strap J-bolt nuts and remove the fuel tank straps (two additional side-straps are used with the 35 gallon fuel tank). Disconnect fuel pump electrical connector from fuel pump module. Slide vent hose assembly and filler tube vent hose through grommets in frame.

Fuel Tank Removal/Installation:

7. Lower tank slightly to provide access to fuel supply line connection on top of fuel pump module.

Fuel Hose Fitting On Fuel Pump Module:

8. Disconnect the fuel supply tube from the fuel pump module.
9. Disconnect fuel vapor line from pressure relief rollover valve.
10. Lower tank from vehicle.

INSTALLATION
1. Place fuel tank on top of transmission jack and position under vehicle. Slide vent hoses and filler tube vent hose through grommets in frame.
2. Raise the tank until the fuel supply line and pump/gauge sending unit connector can be connected to the fuel pump module.

Fuel Tank Strap Tightening B Series Vans:

3. Install retaining tank straps, J-bolts and nuts. Tighten nuts to specification shown. Do not over tighten nuts or distort tank.
4. Connect fuel filler tube and vent hoses. Install new hose clamps of the original type.
5. Connect battery cable to battery.
6. Fill fuel tank.
7. Install fuel tube filler cap.