Aft of Axle Fuel Tank

E-250, E-350 With 7.5L Engine And Electric Fuel Pump(s) Fuel System - Aft Of Axle Installation:

E-250, E-350 Cutaway Models Fuel System - 7.5L Engine With Electric Fuel Pumps:

NOTE: 7.5L model is shown, others are similar.

Removal

1. Insert a siphon through the fuel filler pipe assembly and drain the fuel into a suitable container.
2. Raise the rear of the vehicle.
3. To avoid electrical sparking at the tank, disconnect the ground cable on the vehicle battery. Then disconnect the fuel gauge sending unit wire at the fuel tank.
4. Loosen the clamps on the fuel filler hose and vent hose at the tank neck. Disconnect the hoses from the tank.
5. Loosen the fuel line hose clamp and disconnect the fuel line hose from the fuel gauge sending unit.
6. Support the tank in position. Remove the nuts that attach the mounting straps to the "T" bolts. NOTE: The "T" bolts are attached to body brackets located at the rear of the tank. Disengage the straps from the J-bolts and the front body brackets and lower the tank enough to gain access to the vapor valve. (All vehicles with evaporative emissions systems will be equipped with vapor emission control valves).
7. Disconnect the vapor hose from the vapor control valve.
8. Lower the fuel tank and remove it from underneath the vehicle.
9. If the fuel gauge sending unit is to be removed, turn the unit retaining ring counterclockwise and remove the sending unit retaining ring and gasket.
10. If the vapor control valve is to be removed, pull it out of the grommet located in the top of the tank and remove the grommet.

Installation

1. If the fuel gauge sending unit was removed, scrape away the old gasket material from the unit mounting surface on the fuel tank. Using a new gasket, position the fuel gauge sending unit to the fuel tank and secure with the retaining ring.
2. If the vapor control valve was removed, install the grommet in the tank opening and press-fit the valve into place.
3. If the insulator pads were worn or damaged, remove the material and install new pads.
4. Attach the front ends of the mounting straps to the front body brackets.
5. Raise the tank high enough to connect the vapor hose to the vapor valve.
6. Secure the strap ends to the J-bolts with the attaching nuts. Tighten nuts to 10-14 Nm (7-11 ft-lbs).
7. Connect the fuel line hose to the fuel gauge sending unit.
8. Connect the fuel filler hose to the filler neck and vent neck at the tank. Tighten hose clamps to 2.82- 3.95 Nm (25-35 in-lbs).
9. Connect the vehicle battery ground cable removed in Step 2 of the removal procedure. Connect the fuel gauge sending unit wire.
10. Fill the tank and check all connections for leaks.