Fuel Tank Replacement (Commercial/RV/Cutaway Van)
TOOLS REQUIREDJ 39765 Fuel Sender Locknut Wrench
REMOVAL PROCEDURE
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. This must be done with a frame hoist to allow the rear suspension to hang.
4. Remove the filler hose (3) and 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.
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 the J 39765.
2. Raise the tank and reconnect the electrical connector at the sender.
3. Reconnect the fuel feed and vapor hoses. Refer to Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar).
4. Raise the tank (2) fully and reinstall the tank shield.
NOTE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
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 tiller cap.
NOTE: Refer to Methanol Fuel Notice in Service Precautions.
8. Reconnect the negative battery cable.
IMPORTANT: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.
9. Inspect for fuel leaks.
9.1. Turn the ignition ON for two seconds.
9.2. Turn the ignition OFF for ten seconds.
9.3. Turn the ignition ON.
9.4. Inspect for fuel leaks.