IS-14076
Service Bulletin Details
Public Details for: IS-14076
This instruction sheets explains how to replace the fuel tank on h-series vehicles. (replacing older series tanks by newer model)
- 2020 - 2019 - 2018 - 2017 - 2016 - 2015 - 2014 - 2013 - 2012 - 2011 - 2010 - 2009 - 2008 - 2007 - 2006 - 2005 - 2004 - 2003 -
Models from 2020
2020 PREVOST H3-45 |
2020 PREVOST H3-45 VIP |
Models from 2003
2003 PREVOST H3-41 |
2003 PREVOST H3-45 |
IS-14076 Instruction Sheet FUEL TANK REPLACEMENT ON H-SERIES VEHICLES (Replacing older series tanks by newer model) 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 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 506758 Neoprene Padding 1-1/2 x 1/6 680536 Rubbing Alcohol 1 680532 Sika 221 Sealant 1 As req. NOTE Material can be obtained through regular channels.IS-14076 Page 2 / 11 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. IS-14076 Page 3 / 11 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). NOTE -Apply medium strength thread locker on the conical nut threads (Loctite blue 243 or similar). IS-14076 Page 4 / 11 -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). IS-14076 Page 5 / 11 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. 4. Disconnect the hoses from the old tank accessory plate. 5. Remove the hose fittings from the bottom of the old tank accessory plate. IS-14076 Page 6 / 11 6. Remove all fittings and accessories from the plate (top side). - Overflow valve Pressure valve Fuel Sender Fuel hose fittings (clean threads as necessary) 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. IS-14076 Page 7 / 11 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. 10. Install the fuel sender and cork gasket # 531419 (put sealer on the hex screw threads). IS-14076 Page 8 / 11 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. 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. IS-14076 Page 9 / 11 NOTE -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. IS-14076 Page 10 / 11 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. NEW TANK RE-INSTALLATION QUICK NOTES - Do not reuse damaged or corroded fasteners when reinstalling the tank. . - Remove paint, oxidation and grime from the support mounting points on both support and vehicle. - Don’t forget to reinstall the antistatic strap at the back-left mounting point of the support. - Torque the support fasteners to 55 ft-lb. IS-14076 Page 11 / 11 - Apply color guard on the fuel sender connections. - 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)