Replacing Your Fuel Tank: A Step-By-Step Guide For Beginners

Changing a fuel tank is a complex process that requires careful preparation and execution. It is important to ensure that you have the necessary tools and safety equipment before beginning the task. Here are some key steps to follow when changing a fuel tank:

1. Drain the old fuel tank: Before installing a new fuel tank, completely drain the old tank by either using a drain plug or removing one of the fuel lines.

2. Disconnect the fuel lines: Detach all fuel lines, including the fuel supply line, fill tube, and vent line, from the old tank.

3. Remove the rear suspension: Depending on the vehicle, you may need to drop the rear suspension to access the fuel tank. Disconnect the shock absorbers and brake lines, and use a jack to support and lower the assembly.

4. Remove the fuel tank straps: Loosen the nuts on the metal straps holding the fuel tank in place, and remove the straps.

5. Install the new fuel tank: Place the new fuel tank in the vehicle and secure it with the metal straps. Reattach the fuel lines and fill the tank with fuel.

Characteristics of Changing a Fuel Tank

Drain the old fuel tank

Before you can install your new fuel tank, you need to remove the old tank. The first step in this process is to drain the fuel from the old tank. This is important to prevent lasting damage to your engine.

Many tanks have a small stop valve on the body of the tank that allows you to drain the fuel neatly. If this is the case, simply loosen the valve and let the fuel run out into a fuel can. Make sure you do this in a well-ventilated area, as fuel fumes can be hazardous to your health and are highly flammable.

If your car does not have a fuel tank valve, you will need to remove one of the fuel lines and use it to drain the tank. There should be two fuel lines going into the tank. The smaller line at the bottom of the tank directs the fuel into the engine, while the larger line at the top is used for filling the tank. Detach both lines from the old tank.

If you are dealing with a car, you can run the car close to empty if possible. Unless you have the wrong fuel in the tank, turn the car on and run the gas down towards empty by driving around. Park the car and let it cool before beginning to drain it. This will decrease the amount of pumping and draining you have to do and leave you with less gas to store or dispose of.

If you are dealing with a boat, you may want to run your boat to reduce the fuel level. Less than 1/8 of a tank is a good range to have on the boat's fuel gauge before draining it. If necessary, go for a quick ride before draining your tank.

You can drain a fuel tank using a hose and your mouth, but this is not recommended as it carries the risk of inhaling toxic fumes and swallowing gasoline. Instead, you can use a fuel siphon system or a manual pump. These are available to purchase in most auto stores.

If you are using a manual pump, submerge the suction pump in the gas tank and attach it to a hose. Make sure you have enough hose to reach the bottom of the tank. Put the other end of the hose in a container to catch the fuel and start operating the manual pump until the fuel starts flowing through the hose.

Disconnect the fuel lines

Disconnecting the fuel lines is a crucial step in changing a fuel tank. Here is a detailed guide on how to do it:

First, it is important to note that there is a degree of danger when dealing with fuel tanks due to the risk of ignition. Therefore, it is recommended to work in a well-ventilated area and have a fire extinguisher nearby. Additionally, make sure to drain the fuel tank completely before beginning any work.

Now, to disconnect the fuel lines, follow these steps:

• Identify the fuel lines: There are usually two fuel lines connected to the tank. The smaller line at the bottom of the tank directs fuel to the engine, while the larger line at the top is used for filling the tank. There may also be a third line, known as an air-line, which allows for a decrease in pressure as the fuel travels through the tank.
• Gather the necessary tools: You may need special tools to disconnect the fuel line fittings. Consult your vehicle's service manual to determine the specific tools required for your car.
• Disconnect the lines: Carefully detach all the lines from the old tank. Pay attention to the clamps and fittings, as you may need to loosen or remove them to separate the lines.
• Take pictures and notes: Before disconnecting the lines, it is a good idea to take pictures of the setup and make notes on which lines go where. This will help you during the reassembly process.
• Handle the fuel carefully: Fuel is highly toxic and flammable, so exercise extreme caution when working around it. Make sure to catch the draining fuel in a proper receptacle, such as an EPA/Underwriter's Laboratory-approved gas container.

By following these steps, you can safely disconnect the fuel lines from your fuel tank, preparing you for the next steps in changing your fuel tank. Remember to stay organized, work in a well-ventilated area, and prioritize safety throughout the process.

Remove the fuel tank straps

Removing the fuel tank straps is a crucial step in changing a fuel tank. Here are some detailed instructions to guide you through the process:

Firstly, locate the fastening system that holds the fuel tank in place. Typically, there are two straps that wrap around the tank, with their ends attached to bolts that fasten through a bracket on the vehicle's frame. Some vehicles may have a different setup, with two support frames and four bolts. Identify which type your vehicle has before proceeding.

Once you've located the straps, the next step is to loosen the bolts that hold them in place. Use the appropriate tool, such as an open-end wrench, to loosen the bolts. Be careful not to completely remove the bolts, as you want to avoid the tank falling suddenly.

As you finish loosening the bolts, carefully lower the fuel tank towards the ground. You may be able to use a low-profile floor jack to assist with this step, but ensure your car is jacked up high enough to allow this.

Now, you can remove the straps from around the tank. Gently pull them out and set them aside, being careful not to kink or damage them in the process. With the straps removed, the fuel tank should be free to move.

If you need to remove the tank completely, you can now drag it out from under the car. Remember to perform any necessary maintenance or repairs, and when you're done, simply follow these steps in reverse to reinstall the tank.

It's important to work carefully and methodically throughout this process, especially as you're dealing with fuel, which can be dangerous. Always work in a well-ventilated area and have a fire extinguisher nearby.

Drop the rear suspension

Dropping the rear suspension is necessary when an axle is blocking access to the fuel tank. Here's a detailed guide on how to do it:

First, ensure you have the necessary tools, including car jacks, a spanner set, a wrench set, and a floor jack. Place your vehicle on a flat, hard, and level surface. Remove any fuel from the vehicle using a fluid pump and container. This step is crucial for safety reasons and to make the tank lighter, making it easier to remove.

Next, secure the vehicle by placing wheel chocks around the front tires. Then, use a hydraulic floor jack to raise the car, working on one side at a time, and lift the rear of the vehicle. Place jack stands under the body pinch weld and lower the vehicle onto the stands.

Now, locate the fuel tank under the vehicle. Disconnect the brake lines to avoid damaging them. If your vehicle has shocks, disconnect them as well. Use the floor jack to rest the rear suspension beam at the centre, and finally, bring the entire assembly down to the floor.

By following these steps, you will have successfully dropped the rear suspension, providing you with the necessary access to remove and replace the fuel tank. Remember to work carefully and take appropriate safety precautions when performing any vehicle maintenance or repairs.

Install the new fuel tank

Now that you've drained the old fuel tank and removed it, it's time to install the new one.

Prepare the new fuel tank

Before you install the new fuel tank, ensure that you have the correct tank for your vehicle's specific make and model. Place the new tank in a safe area, preferably off the ground, and away from any clutter or flammable materials.

Lower the new fuel tank into place

With the old tank removed, you can now lower the new tank into place. This process will be the reverse of the removal process. Place the new tank in the same position as the old one, ensuring it is securely held in place by the straps and bolts.

Reattach the fuel lines and electrical connections

Now, reconnect the fuel lines and electrical connectors to the new tank. This process will depend on your vehicle's specific configuration, so refer to the manufacturer's instructions or a repair manual for detailed steps. Ensure all connections are secure to avoid leaks.

Refill the new fuel tank

With the new tank installed and the connections secure, you can now refill the tank with fuel. Be careful not to overfill the tank, and ensure that there are no leaks around the connections or the tank itself.

Test the vehicle

Once the new tank is installed and filled with fuel, start the vehicle and check for any signs of leaks or issues. Let the vehicle run for a few minutes, and inspect the tank and connections for any fuel drips or vapours. If there are no issues, your vehicle is ready to go!

Frequently asked questions