Fuel Tank Information
DRAIN THE FUEL TANKS1. To avoid electrical sparking at the tank, disconnect the battery ground cable.
2. Using a Rotunda Pump Unit #034-00002 or equivalent, pump the fuel out of both the rear and front (if so equipped) fuel tanks into a suitable container.
3. Raise the vehicle on a hoist.
FIGURE 5:
1. 22-Gallon Rear Tank
a. Loosen the hose clamps securing the fuel fill hose and fill vent hose to the tank. Disconnect the hoses.
b. On 1985-1/2 to 1987 vehicles, disconnect the vent valve 1/4 inch diameter rubber vapor hose at its connection with the steel 1/4 inch vapor line. This will be at the rear of the tank on vans and Clubwagons and at the front of the tank on cutaways and stripped chassis.
c. On vehicles based on cutaway or stripped chassis, disconnect the fuel supply and return lines at the rear tank fuel pump/fuel gauge sender. On vehicles using nylon lines, disconnect by prying out the push connect retention clevises. On vehicles using steel lines, disconnect by loosening the hose clamps.
NOTE: Save clevises or hose clamps for reinstallation of tank.
d. Support the fuel tank using a transmission jack. Loosen the rear fuel tank retention straps or support bars and lower the tank.
NOTE: On some vehicles, it may be necessary to loosen the exhaust pipe from its rear support bracket for clearance.
e. Remove the fuel fill and fill vent restrictor tubes from the tank fill and fill vent openings.
FIGURE 6:
f. Insert the new 4.5 inch fill vent restrictor tube (Item 15) into the fill vent opening (See Figure 6).
NOTE: Be certain to use the correct part. The standard 22-Gallon Rear Tank uses the longer non-flexible vent restrictor provided in the kit.
g. Raise the fuel tank back into position, being careful not to pinch any vapor or fuel lines against body sills, frame brackets, or any other hardware that may be present. Be sure wiring to the fuel pump/gauge sender has clearance.
FIGURE 8:
h. Frame mounted rear tank only (cutaway or stripped chassis based vehicles).:
- The four nuts on the rear tank support mounting bolts must be tightened to 41 to 57 N-m (30 to 42 ft.lb.) (See Figure 8).
FIGURE 7:
i. Body mounted rear tank only (van and Clubwagon based vehicles):
- The two support nuts must be tightened until there are 1.65 to 1.85 inches of thread exposed on the mounting bolts. (See Figure 7).
j. Nylon lines only: Re-attach the fuel supply and return lines at the fuel pump/fuel gauge sender using the clevises removed in Step "c".
NOTE: Pull on the lines to make sure the connectors are fully engaged.
k. Steel lines only: Reinstall the original hose clamps. The small steel line is the return line, and houses a spring clamp. The larger supply line uses the screw clamp and it must be torqued to 1.6 to 2.3 N-m to 20 in.lb.).
l. If the exhaust pipe was loosened, re-secure it.
m. On 1985-1/2 to 1987 vehicles, locate the 1/4 inch vapor hose that was left hanging loose at the front or rear of the tank in Step "b". Re-connect the hose to the 1/4 inch diameter steel vapor line.
n. Disconnect the fuel filler pipe from the body by loosening the screw clamp that attaches it to the under body (if used) and removing the three screws that attach it to the body (vans only, cutaways and stripped chassis mount the neck in a rubber grommet).
o. Remove the filler pipe and discard it. Retain all filler hoses and screw clamps.
p. Cutaway and stripped chassis only: Remove and discard the rubber filler pipe retention grommet.
q. Cutaway and stripped chassis only: Using the template (Kit E3UZ-9000-G) (Kit E) locate and drill three holes, 1/4 inch in diameter, around the filler opening in the body-mounted fill pipe support.
r. Install the new filler pipe (vans use Kit E3UZ-9000-E) (Kit X) (Item 1), (cutaways and stripped chassis use Kit E3UZ-9000-G) (Kit E) (item 1), using three screws (Item 2). Torque the screws to 1.7 to 2.8 N-m (15 to 25 in.lb.).If the old filler pipe was secured to the body with a screw clamp, replace the clamp and torque it to 3 to 4 N-m (27 to 35 in.lb.).
s. Reconnect the fill and fill vent hoses. Tighten the hose screw clamps to 3 to 4 N-m (27 to 35 in.lb.).
2. 38/40-Gallon Rear Tank
a. Disconnect the fuel supply and return lines at the front of the tank. On vehicles using nylon lines, disconnect by prying out the push connect retention clevises. On vehicles using steel lines, disconnect by loosening the hose clamps.
NOTE: Save clevises or hose clamps for reinstallation of tank.
b. On 1985-1/2 to 1987 vehicles, disconnect the vent valve 1/4 inch diameter rubber vapor hose at its connection with the steel 1/4 inch diameter vapor line at the front of the tank. On 1983 to 1985-1/2 vehicles, disconnect the 3/8 inch diameter hose that clips to the top flange of the crossmember in front of the tank.
c. Loosen the hose clamps securing the fuel fill hose and the fuel vent hose to the tank. Disconnect the hoses.
d. Support the fuel tank using a transmission jack.
e. Loosen the fuel tank support straps and lower the tank.
NOTE: On some vehicles, it may be necessary to loosen the exhaust pipe from its rear support for clearance.
f. Remove the fuel fill and fill vent restrictor tubes from the tank fill and fill vent openings.
FIGURE 6:
g. Insert the new flexible 6.5 inch fill vent restrictor tube (Item 16) into the fill vent opening (See Figure 6).
NOTE: Be certain to use the correct part. The rear tank uses the flexible insert, provided in the kit.
h. Using the transmission jack, raise the tank into place, being careful not to pinch or crush the wiring harness or any vapor line or fuel liens against the body sills, frame brackets, or ambulance body floor members.
FIGURE 9:
i. Re-attach the support straps. Be certain that the 5/16 inch vent valve hose which is a part of the new valve and hose assembly, can be reached from the front of the tank. The two front mounting bolts must be tightened to 102 to 142 N-m (75 to 105 ft.lb.). The rear support nuts must be tightened to 27 to 34 N-m (20 to 25 ft.lb.) (See Figure 9).
FIGURE 9:
j. Route the 5/16 inch and 3/8 inch (1983 to 1985-1/2 only) vent valve hose to the top flange of the crossmember in front of the tank and re-attach it. (See Figure 9).
k. Nylon lines only: Re-attach the fuel supply and return lines to the lines at the front of the tank which connect to the fuel pump/fuel gauge senders, using the clevises removed in Step "a".
NOTE: Pull on the lines to make sure the connectors are fully engaged. The 3/8 inch black clip is for the supply line; the 5/16 inch white clip is for the return line.
l. Steel lines only. Re-install the original hose clamps. The smaller steel line is the return line and it uses a spring clamp. The larger supply line uses the screw clamp, and it must be torqued to 1.6 to 2.3 N-m (24 to 20 in.lb.).
m. If the exhaust pipe was loosened, re-secure it.
n. On 1985-1/2 to 1987 vehicles, locate the 1/4 inch vapor hose that was left hanging loose at the front of the tank in Step "b". Re-connect the hose to the 1/4 inch diameter steel vapor line.
o. Disconnect the fuel filler pipe from the body by loosening the screw clamp that attaches it to the under body (if used) and removing the three screws that attach it to the body (vans only, cutaways and stripped chassis mount the neck in a rubber grommet).
p. Remove the filler pipe and discard it. Retain all filler hoses, and screw clamps.
q. Cutaway and stripped chassis only: Remove and discard the rubber filler pipe retention grommet.
r. Cutaway and stripped chassis only: Using the template (Kit E3UZ-9000-G (Kit E) locate and drill three holes, 1/4 inch in diameter, around the filler opening in the body-mounted fill pipe support.
s. Install the new filler pipe (vans use Kit E3UZ-9000-E) (Kit X) (Item 1), (cutaways and stripped chassis use Kit E3UZ-9000-G) (Kit E) (Item 1),using three screws (Item 2). Torque the screws to 1.7 to 2.8 N-m (15 to 25 in.lb.). If the old filler pipe was secured to the body with a screw clamp, replace the clamp and torque it to 3 to 4 N-m (22 to 35 in.lb.).
t. Reconnect the fill and fill vent hoses. Tighten the hose screw clamps to 3 to 4 N-m (27 to 35 in.lb.).
3. Midship (Front) Tank and Vapor Hose
a. Loosen the hose clamps securing the fuel fill hose and fill vent hose to the tank. Disconnect the hoses.
b. On 1985-1/2 to 1987 vehicles, disconnect the vent valve 1/4 inch diameter rubber vapor hose at its connection with the steel, 1/4 inch vapor line on the right side of the tank.
c. Disconnect the fuel supply and return lines at the fuel pump/fuel gauge sender. On vehicles using nylon lines, disconnect by prying out the push connect retention clevises. On vehicles using steel lines, disconnect by loosening the hose clamps.
NOTE: Save clevises or hose clamps for reinstallation of tank.
d. Support the fuel tank using a transmission jack. Loosen the rear fuel tank retention and remove the tank.
e. Remove the fuel fill and fill vent restrictor tubes from the tank fill and fill vent openings.
FIGURE 6:
f. Insert the new 3.0 inch fill vent restrictor tube (Item 14) into the fill vent opening (See Figure 6).
9. On 1985-1/2 to 1987 vehicles, remove the 3/8 - 1/4 inch adaptor and hose from the vapor valve.
h. Attach the large diameter end of the new vent valve vapor hose (Item 10) to the vent valve. Allow the free end of the hose to hang on the right side of the tank.
i. Before raising the fuel tanks, be sure that the electrical wiring, vapor vent lines, and fuel lines are positioned to have clearance to body sill and frame members. Clip, tape, or band them if required to stay clear of any Ambulance Manufacturer modifications which may exist (especially in mid-ship tank area which has been modified by the Ambulance Manufacturer).
NOTE: Pull on the lines to make sure the connectors are fully engaged.
j. Raise the fuel tank back into position being careful not to pinch any wiring, vapor or fuel line against body sills, frame brackets, or any other hardware that may be present.
FIGURE 10:
k. Install the fuel tank support straps and tighten the strap nuts until 1.25 to 1.50 inches of threads are exposed. (See Figure 10).
l. On 1985-1/2 to 1987 vehicles, connect the new vent valve vapor hose to the 1/4 inch steel vapor line on the right side of the tank.
m. Disconnect the fuel filler pipe from the body by loosening the screw clamp that attaches it to the underbody (if used) and removing the three screws that attach it to the body (vans only, cutaways and stripped chassis mount the neck in a rubber grommet).
n. Remove the filler pipe and discard it. Retain all filler hoses and screw clamps.
o. Cutaway and stripped chassis only. Remove and discard the rubber filler pipe retention grommet.
p. Cutaway and stripped chassis only using the template (Kit E3UZ-9000-G) (Kit E) locate and drill three holes, 1/4 inch in diameter, around the filler opening in the body-mounted fill pipe support.
q. Install the new filler pipe (vans use Kit E3UZ-9000-E) (Kit X) (Item 1), (Cutaways and stripped chassis use Kit E3UZ-9000-G) (Kit E) (Item 1), using three screws (Item 2). Torque the screws to 1.7 to 2 8 N-m, (15 25 in.lb.) If the old filler pipe was secured to the body with a screw clamp, replace the clamp and torque it to 3 to 4 N-m (27 to 35 in.lb.).
NOTE: Reconnect the fill and fill vent hoses. Tighten the hose screw clamps to 3 to 4 N-m (27 to 35 in.lbs.).