Midship Fuel Tank

E-250, E-350 With 7.5L Engine And Electric Fuel Pump(s) Fuel System - Midship Fuel Tank 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 vehicle.
3. To avoid electrical sparking at the tank, disconnect the ground strap on the vehicle battery. Then disconnect the fuel gauge sending unit wire at the fuel tank.
4. Support the tank in position. Disengage the mounting strap ends attached to the frame side rail. Remove the other end from the tank support by rotating the strap to disengage the 11T" shaped hook end.
5. Lower the tank enough to gain access to the vapor valve, fuel filler hose, fuel vent hose, and fuel line hose. Loosen the attaching clamps and disconnect the hoses.
6. Lower the tank and remove it from underneath the vehicle.
7. If the fuel gauge sending unit is to be removed, turn the retaining ring counterclockwise and remove the sending unit, retaining ring and gasket.
8. If the vapor control valve is to be removed, turn the unit retaining ring counterclockwise and remove the vapor valve, retaining ring and gasket.

Installation

1. If the fuel gauge sending unit was removed, scrape away all 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 valve was removed, install the valve in the tank opening, following the procedure described for the fuel gauge sending unit installation.
3. If the insulation tape was worn or damaged, remove the material and install new pieces approximately 41.9mm (16.5 inches) long, (two pieces).
4. Attach the "T" hook mounting strap ends in the tank supports. Raise the tank high enough and connect the vapor hose, fuel filler hose, fuel vent hose, and fuel line hose. Tighten the clamps that attach the hoses to the mating tank parts.
5. Attach the mounting straps stud end to the frame side rail with attaching nuts and tighten to 31.8-38.1 Nm (31.8-38.mm [1.25-1.50 inches] exposed thread length).
6. Connect the vehicle battery ground cable removed in Step 3 of the removal procedure. Connect the fuel gauge sending unit wire.
7. Fill the tank and check all connections for leaks.