Commercial/RV Cutaway Van

REMOVAL PROCEDURE
1. Drain the fuel from the tank. Refer to Draining Fuel Tank.
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 and the vent hose from the fuel tank.
4. Support the fuel tank.
5. Remove the fuel tank straps.
6. Lower the fuel tank and the fuel tank shield.
7. Disconnect the fuel feed and the vapor hoses. Refer to Servicing Quick Connect Fittings. Service and Repair
8. Disconnect the electrical connections at the fuel sender assembly.
9. Remove the fuel tank.
10. Use tool J 36608 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 tool J 36608 in order to install the fuel sender assembly.
3. Raise the tank slightly.
4. Reconnect the fuel feed and vapor hoses. Refer to Servicing Quick Connect Fittings. Service and Repair
5. Reconnect the electrical connector to the fuel sender assembly.
6. Raise the fuel tank fully.
7. Install the fuel tank shield.
8. Install the fuel tank brackets with the insulator strips in place.

NOTE: The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gage will indicate fuel remaining in the tank when the tank runs dry.

Tighten
Tighten the fuel tank straps to 12 Nm (10 lb. ft.).

9. Install the fuel filler neck to the fuel tank.
10. Replenish the fuel in the fuel tank.
11. Reinstall the fuel tank filler 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.