Fuel Tank Draining and Removal/Installation

FUEL TANK DRAINING AND REMOVAL/INSTALLATION PROCEDURE

DRAINING FUEL TANK
1. Remove fuel tank filler tube cap to release fuel tank pressure.
2. Perform Fuel System Pressure Release Procedure. Service and Repair
3. Raise vehicle on hoist.
4. Drain fuel into an approved portable holding tank or a properly labeled gasoline safety container.
5. If fuel pump operates, fuel can be drained through fuel supply hose. The DRB scan tool can be used to operate the electric fuel pump.
6. If pump does not operate, but fuel level in fuel tank is below the fuel filler hose, fuel can be siphoned through fuel filler hose. The hose will have to be disconnected from filler neck.
7. If fuel tank is full, and fuel pump does not operate, drain fuel from filler neck. Refer to following step (a).
a. Support fuel tank with a transmission jack.
b. Loosen fuel tank mounting straps with passenger side fuel strap loosened slightly more than driver side strap.
c. Lower the tank slightly.
d. Loosen the filler neck-to-filler hose clamp.
e. Slide clamp back on hose. Wrap shop towels around fuel filler hose to absorb any spilled fuel.
f. Disconnect filler hose from filler neck.
g. Drain fuel tank through filler neck.

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.

4. Raise vehicle on hoist and disconnect filler vent hose and filler hose (Fig. 30). Remove the vent hoses from hose routing bracket attached to the top of the frame rail.

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

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.

Pressure Relief/Rollover Valve:

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.