IS-14076A

Instruction Sheet

FUEL TANK REPLACEMENT ON H-SERIES VEHICLES
(Replacing older series tanks by newer model)
Revision: A

Added mounting hardware and shims to kit:

2020-02-24

MATERIAL
Kit #030009 includes the following parts:
Part No.

Description

Qty

030007

Fuel Tank

1

032956

Gasket, Accessory Plate

1

033962

Inner Frame

1

033959

Accessory Plate

1

032938

Gasket, Fuel Filler

2

531443

Gasket, Overflow

1

507356

O-ring, Overflow

1

531419

Fuel Gauge Gasket

1

531427

Gasket, Pressure Relief Valve - Small

1

531428

Gasket, Pressure Relief Valve - Large

1

5001392

Copper Washer 6x12x1.5

10

5001941

SCREW CAP HEX M12X1.75X120 G10.9

2

500806

SCREW CAP HEX M12-1.75X35 G10.9

4

500811

NUT HEX STO N500 M12-1.75 G10

6

500958

FLAT WASHER SS .531X1.062X.095 (M12,1/2)

12

030082

SHIM U 3.175MM

4

030083

SHIM U 0.953MM

4

IS-14076

Instruction Sheet (English)

1

FI-14076

Instruction Sheet (French)

1

Other parts that may be required:
Part No.

Description

Qty

680098

Loctite 567 Thread Sealer PFTE

1

680066

ADFAST 5014-1 Superglue or equivalent

1

680038

Loctite 243 medium strength Thread locker (blue) or equivalent

1

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506758

Neoprene Padding 1-1/2 x 1/6

As req.

680536

Rubbing Alcohol

1

680532

Sika 221 Sealant

1

NOTE
Material can be obtained through regular channels.

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.

PART 1: Tank Support Preparation
1. Empty and remove the old gas tank (and support) from the vehicle.
2. Remove the three metal braces holding the gas tank to the support.

3. Remove the gas tank from the support.
4. Clean the support surfaces from dirt, grime and debris. Replace the padding on the support rails
as needed.

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PART 2: Tank to support installation
1. Install the new tank on the support making sure that the tank bottom drain plug is centered in the
support opening.

2. Install the support braces over the tank and tighten the braces to the support using the previously
removed hardware (springs and conical nuts).

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NOTE
-Apply medium strength thread locker on the conical nut
threads (Loctite blue 243 or similar).

-Tighten the conical nuts until the springs are bottoming-out
(fully compressed) then back out three (3) complete turns.

PART 3: Tank hardware installation

WARNING
Coat the threads of all bolts passing through the new tank or accessory plate with Loctite 567 PFTE
Teflon paste or equivalent. Do not use silicone (RTV) sealant anywhere during this installation.
1. Remove the complete accessory plate (with hoses, hardware and inner frame) from the old tank
(clean hex bolt threads and discard cooper washers).

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2. Remove the two tank fillers from the old tank; clean flanges and threads (discard old gaskets).

3. Reinstall the filler tubes on the new fuel tank using the two supplied gaskets # 032938. Reuse the
filler tubes hardware and apply Teflon paste on the stud threads.

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4. Disconnect the hoses from the old tank accessory plate.
5. Remove the hose fittings from the bottom of the old tank accessory plate.

6. Remove all fittings and accessories from the plate (top side).
-

Overflow valve
Pressure valve
Fuel Sender
Fuel hose fittings (clean threads as necessary)

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7. Secure the plate in a vice and reinstall the top and bottom hose fittings on the new accessory plate
using thread sealant on the fitting threads (do not install fuel sender or valves).

NOTE
To avoid interference problems
when screwing the hose fittings,
install the fittings before the
valves and fuel sender unit.

8. Install the overflow valve, gasket and O-ring (part # 531443 & 57356), put sealant on the screw
threads.

9. Install the two part pressure valve with lower gasket # 531427 (put sealant on the threads) and upper
gasket # 531428.

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10. Install the fuel sender and cork gasket # 531419 (put sealer on the hex screw threads).

11. Install the hoses at the bottom of the plate and tighten them making sure that their natural curve will
make them lay flat at the bottom of the tank.

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12. Inside the tank, install the accessory plate inner frame (reuse the two tapered screws), apply Sika 221
grey sealant over the screw heads.

13. Install the accessory plate gasket # 032956 over the tank opening (clean both sides of the gasket
with rubbing alcohol first) and install the assembled accessory plate on the tank (reuse mounting
hex screws with the new supplied copper washers # 5001392; apply thread sealant on all
screws).

WARNING
-Make sure that the tank interior is clean and free of debris before installing the accessory plate on the
tank.
-When installing the accessory plate, the hoses must lay flat at the bottom of the tank.

NOTE

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-It is also possible to bond the gasket to the bottom of the accessory
plate using quick set superglue.

-Apply only a small drop of glue at the exterior edge of the screw holes
as shown.

14. Pressure-test the tank at 3 psi. Install caps at the fuel filler ends, cap the vent hose and fuel line connections and connect a test valve with low pressure gauge at the tank outlet.

15. Spray soapy water and check for leaks (bubbles) around:
-

Accessory plate perimeter.

-

Fuel fittings.

-

Pressure and overflow valves.

-

Fuel sender.

-

Both fuel filler flanges.

NOTE
- The drain plug at the bottom of the tank is tested at the factory and does not need to be retested.
- If the pressure relief valve opens at 3 psi or below, the valve is defective and must be replaced.

Correct leaks as necessary, if no leaks are found, the tank is ready for re-installation.

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NEW TANK RE-INSTALLATION
16. Install new cradle mounting
hardware: and any static strap
removed earlier.
500806, Screw M12
500811,
Nut
500958, Washer 2x

35mm
M12

17. Tighten to 82 lb-ft. Apply
torque seal marks
18. Repeat on the three other locations.

FIGURE 1: LONGITUDINAL MOUNTING SCREWS (4 LOCATIONS)

19. The mounting lugs on the vehicle frame may be bent slightly inward. Bend them slightly
outward to make them straight
with a hammer and chisel.
Mounting lug geometry may
vary across model years.
20. Blow clean and try to insert
one shim 030083 between the
mounting surface of the cradle
beam and the ear.

FIGURE 2: MOUNTING LUGS

21. If you feel interference while
inserting the shim, the contour
weld on the cradle tubing may
need to be lightly ground down
in this location with a thin cutting wheel to have a flat surface for the shim. (Figure 4).
22. Clean and dry the mounting
surfaces.

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FIGURE 3: CRADLE TUBING MOUNTING SURFACE

23. Loosely install new hardware
and any static strap removed
earlier.
5001941, Screw M12x120mm
500811, Nut M12
500958, Washer 2x
24. Insert the required amount of
shims 030082 or 030083 between the mounting lugs and
the cradle tubing.
Note: To ease shim insertion,
you may need to pry lug and
tube open with a flat head
screwdriver (Figure 5). Gently
tap the shim with a hammer.

FIGURE 4: SCREW AND SHIM INSTALLATION

NOTE
Shim arrangement will vary depending on vehicle series and model year.
Shims may be needed on both sides of the tube.
Shims can be stacked to achieve desired fit.
In all situations the shims should be snug between mounting ear and tube.
25. Tighten to 82 lb-ft.
26. Apply torque seal mark.
27. Proceed to other side.

FIGURE 5 : END RESULT. SHIM ARRANGEMENT MAY VARY.

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28. Apply color guard on the fuel
sender connections.

29. Overflow hose must now pass to
the right of the tank (see images
below).

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)