The Complexities Of Fuel Tank Replacement: A Comprehensive Guide

Replacing a fuel tank is a big job, but it's not complicated. It's important to be aware of the dangers of working with fuel, which can ignite or explode, and take appropriate precautions. Before starting, drain the tank completely and responsibly, and work in a well-ventilated area with a fire extinguisher to hand. You'll also need car jacks, a spanner set, a wrench set, hose clamps, and a fuel can. It may be necessary to drop the suspension and remove the driveshaft, and you'll need to detach the fuel lines. The tank is held in place by two straps, with two fuel line connectors and an electrical connector, and possibly a separate ground wire.

Draining the fuel tank

Before you begin to drain your fuel tank, it is important to note that fuel is highly flammable and toxic. You should always drain your tank in a well-ventilated area and have a fire extinguisher to hand. It is also important to store the drained fuel in the correct container.

There are several methods to drain your fuel tank. The first is to use a hose. Insert the hose into the tank and suck on the other end to start the flow of fuel. Then, transfer the fuel to a container. This method is straightforward and does not require any specialised equipment. However, it carries the risk of inhaling toxic fumes and the fuel getting into your mouth, which is dangerous.

The second method is to use a compressed air system. This process requires tools such as an air compressor, a fuel tank adapter, and a fuel line. Connect the fuel line to the tank adapter and the adapter to the air compressor. Once set up, start the compressor and the pressure will force the fuel out of the tank.

The third method is to use a manual pump. This process requires a manual pump, a fuel tank adapter, and a fuel line. Connect the fuel line to the tank adapter and the adapter to the manual pump. Once set up, start the pump and the fuel will be forced out of the tank. Have a container ready to collect the fuel. When you are done, disconnect the fuel line, turn off the pump, and store the tools.

The fourth method is to drain the fuel tank directly. This method may not work for all cars. Locate the drain plug on your fuel tank, usually near the bottom, and use a wrench to loosen it. As you loosen the plug, fuel will start to drain out. Have a wide-mouthed container, such as a basin, ready to catch the fuel.

Additionally, if your car has been run recently, you can drive around to empty the tank. However, do not do this if you have the wrong fuel in your tank.

Ventilating the area

Changing a fuel tank is a big job, but it can be made safer by ventilating the area. Even when the tank is drained, it will still smell strongly of fuel, so it's important to ensure the area is well-ventilated. Fuel fumes can cause you to pass out, and in the case of petrol, the vapour is extremely flammable.

It's best to avoid working in an integral garage with the door closed. Instead, choose an outdoor space that is open and airy. If you must work in a garage, keep the door open at all times and consider setting up fans to improve airflow.

In addition to ventilating the area, there are several other safety precautions you should take when working with fuel tanks. Avoid smoking or creating any sparks, and do not use a drop light or power cords. Wear gloves and goggles to protect yourself from fuel exposure. Have a fire extinguisher (a Class B extinguisher for petrol fires) nearby in case of any accidents.

By taking these precautions and ensuring the area is well-ventilated, you can help keep yourself and your workspace safe while changing a fuel tank.

Taking notes and pictures

Bag and Label Nuts and Bolts:

You will be removing a lot of different nuts and bolts of various sizes when taking apart components to access and replace the fuel tank. It is crucial to stay organised during this process. A helpful tip is to use plastic bags to group the nuts and bolts and clearly label each bag, specifying which component they belong to. This will make it easier when it's time to reassemble everything.

Take Pictures Before Disassembly:

Before removing any parts, take clear pictures of the areas you will be working on. Capture different angles and pay attention to the positioning and orientation of components, especially the fuel lines and any wiring. These pictures will serve as a valuable reference when putting everything back together, ensuring you reconnect and position items correctly.

Note Removal Techniques:

As you disassemble, make notes on specific techniques or steps you take to remove certain parts. For example, if you need to use a particular tool or technique to loosen a rusted bolt, make a note of it. This will help you when it's time to reassemble, as you may need to use a specific method or tool again.

Document Fuel Line Connections:

Fuel lines are a critical component when working on the fuel tank. Take detailed pictures and make notes of how the fuel lines are connected to the tank and any other components. Note the order and orientation of the lines, as well as the placement of any clips or clamps holding them in place. This will ensure you can properly reconnect the lines during reassembly.

Record Suspension and Driveshaft Adjustments:

In some cases, you may need to drop the suspension or remove the driveshaft to access the fuel tank. Take pictures and make notes on the process of removing these components. Note the order of removal and any adjustments made, such as disconnecting the brake lines or using a floor jack to support the assembly. This information will be crucial when it's time to put everything back together.

Capture Fuel Tank Details:

Before removing the old fuel tank, take pictures of it from multiple angles. Note the positioning of any straps, bolts, or other mounting hardware. Additionally, pay attention to the fuel lines connected to the tank and how they are routed. This will aid in the installation of the new fuel tank and ensure proper alignment and connection of the fuel lines.

By following these steps and taking comprehensive notes and pictures, you will have a valuable reference guide to assist you during the reassembly process. This will help ensure that you can confidently and accurately put everything back together, making the task of changing your fuel tank a more organised and efficient endeavour.

Dealing with rust

Assess the Extent of Rust

Before attempting any repairs or replacement, it is crucial to inspect the fuel tank for rust thoroughly. This includes checking the exterior for deep dents, large cracks, or severe impacts that may indicate structural issues. A thorough inspection of the tank's interior is also necessary to determine the severity of the rust buildup.

Decide Between De-Rusting or Replacement

After assessing the extent of rust, you need to decide whether to attempt to remove the rust or replace the tank altogether. If the tank is too damaged or corroded, de-rusting may not be sufficient, and replacement might be the better option. Consider the condition of the tank, the rarity of the vehicle, and the availability of spare parts in your decision-making process.

Use Abrasive Materials and Cleaning Chemicals

If you decide to remove the rust, you can use abrasive materials such as gravel and loose nuts, combined with water or a compatible cleaning solution, to scour off the rust from the tank's interior. Additionally, cleaning chemicals like vinegar, baking soda, muriatic acid, or isopropyl alcohol can be used to create a chemical reaction that loosens the rust.

Apply Electrolysis

Electrolysis is a cheap and effective method that uses an electric current in an electrolytic bath to remove rust. To perform electrolysis, you'll need a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate. Submerge the gas tank and ferrous metal in the container, connect the corroded part to the negative battery terminal, and the metal to the positive terminal. The electricity will cause the rust to be removed and deposited on the ferrous metal.

Use a High-Pressure Hose

Another method involves using a loose hose and high water pressure. Attach a piece of flexible rubber hose (about 1/4 inch in diameter and 3 feet long) to a pressure washer nozzle, and clamp it to the tank. This will cause the hose to whip around inside the tank, dislodging loose rust and other debris.

Clean and Patch or Replace the Tank

If you choose to replace the tank, it is important to clean and patch any small holes or leaks in the old tank before disposing of it. Use water to swish around inside the tank and remove rust particles. If the holes are minor, use a fuel tank repair kit to seal them. However, if the holes are large or numerous, it is recommended to replace the tank entirely.

Remember to always prioritize safety when working with fuel tanks and flammable substances. Ensure proper ventilation, avoid sparks, and have a fire extinguisher nearby.

Fire safety

Changing a fuel tank is a big job and can be dangerous, especially when dealing with petrol due to its propensity to ignite. Here are some fire safety tips to keep in mind when changing a fuel tank:

Work in a Well-Ventilated Space

Even when the tank is completely drained, it will still give off fuel vapours. Therefore, it is important to work in a well-ventilated area to avoid passing out from the fumes, which could lead to injury. Additionally, petrol vapours are extremely flammable, so working in a well-ventilated area will reduce the risk of accidental ignition.

Drain the Tank Completely

Before beginning any work, ensure that the fuel tank is completely drained and the fuel is stored responsibly in appropriate containers. Most cars have a drain plug at the bottom of the tank that can be undone. Do not drill a hole in the tank as this could create sparks and potentially cause an explosion.

Avoid Sparks

When working with fuel tanks, it is crucial to avoid any potential sources of ignition. Do not smoke, and avoid using power tools or metal tools that could create sparks. If you need to loosen rusted bolts, use non-sparking tools made from brass or wood.

Have a Fire Extinguisher Handy

Fuel is highly flammable and can easily ignite, so it is important to have a fire extinguisher nearby in case of an emergency. Keep it close at hand, not stored away in a cupboard, so that you can quickly and easily access it if needed.

Be Organised

Changing a fuel tank involves removing and working around many different components. Take notes and pictures to keep track of where everything goes, and bag up nuts and bolts, labelling what they are for. This will make it easier to reassemble everything correctly and reduce the risk of leaving loose components that could create a fire hazard.

Replace Old and Corroded Parts

If any parts of the fuel system, such as breather lines, fuel line clips, or fuel tank straps, show signs of corrosion or damage, replace them with new ones. Corroded parts can compromise the integrity of the fuel system and increase the risk of fuel leaks and fires.

Frequently asked questions