Sylvie Willis
Removing a fuel tank from a vehicle is an uncommon but sometimes necessary task. Before attempting to remove a fuel tank, it is important to have the necessary tools and equipment, such as strap bolts, wrenches, screwdrivers, and a jack. It is also important to ensure that the vehicle is on a flat surface, preferably concrete, to avoid fuel spills. When removing the fuel tank, it is crucial to follow the correct steps, such as loosening the gas tank strap bolts and carefully lowering the tank to the ground. Additionally, it is important to address any rust or corrosion inside the tank, which can be done by using a mild solution of muratic acid or a sturdy brush with solvent. Building a custom fuel tank involves taking measurements, choosing the right materials, and considering factors such as weight, corrosion resistance, and ease of welding.
Characteristics and Values of Fuel Tank Pull
| Characteristics | Values |
|---|---|
| Tools and Equipment | Strap bolts, open-end wrench, slotted and Phillips screwdrivers, hose clamps, fuel line fittings, jack, jack stands, pump, fuel-rated containers, rags, fire extinguisher |
| Location | Flat surface, preferably concrete driveway; hard, compacted soil is acceptable |
| Preparation | Locate and loosen fasteners, clamps, and connections; remove fuel; disconnect battery to avoid sparks |
| Fuel Tank Removal | Lower fuel tank to the ground; remove support straps; drag tank sideways from under the car |
| Fuel Tank Installation | Reverse removal process; ensure proper alignment and connections |
| Fuel Tank Design | Consider measurements, fuel pick-ups, vents, filler, straps, sensors, and lines; use cardboard prototype to test fit |
| Fuel Tank Materials | Stainless steel, aluminum, or mild steel with coating; consider corrosion resistance, weight, and weldability |
| Fuel Tank Construction | Divide large tanks into sections or small cells with trap doors or holes to prevent fuel slosh and balance issues |
| Fuel Tank Access | Locate fuel tank lever or button near the driver's side door or inside the access panel; push or pry open the gas tank door |
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What You'll Learn
Prepare the necessary tools and equipment
Preparing the necessary tools and equipment is crucial before attempting to remove or lower a fuel tank. This task is uncommon and should be approached with caution. Here are the essential tools and equipment you will need:
Safety First:
Before starting, ensure you have an assistant to help you with tools and to respond in case of any accidents. Remove the ground cable from your battery to prevent sparks, and locate your vehicle on a flat surface, preferably a concrete driveway, to avoid spills and accidents. Have a fire extinguisher readily available as well.
Tools for Removal:
- Strap bolts: You will need an open-end wrench with the appropriate size (1⁄2 or 9⁄16 inch or 1.3-1.4 cm, or 12-14 mm) to loosen and remove strap bolts.
- Screwdrivers: Have both slotted and Phillips screwdrivers ready for hose clamps.
- Fuel line tools: Special tools are required for disconnecting fuel line fittings.
- Jack and jack stands: A jack can provide support and help lower the fuel tank. Ensure your car is jacked up high enough.
- Fuel pump: A pump is necessary for removing the fuel from the tank.
- Fuel containers: Use fuel-rated containers to safely collect and store the fuel removed from the tank.
- Rags: Have rags handy to wipe up any spills or excess fuel.
Additional Considerations:
- Fuel gauge: Confirm the amount of fuel in your tank by checking the fuel gauge. Most fuel tanks have a capacity of 12 to 20 gallons (45.4 to 75.7 litres).
- Fuel level sensing units: These may need to be specially ordered from a dealer.
- Repair parts: Ensure you have access to repair parts before starting the project.
By gathering these tools and equipment, you will be well-prepared to safely and effectively remove or lower a fuel tank.
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Loosen the bolts and clamps
Before attempting to loosen the bolts and clamps of a fuel tank, ensure you have the necessary tools and equipment. Different fasteners, clamps, and connections must be removed or loosened to detach a fuel tank. These include strap bolts, hose clamps, and fuel line fittings. It is also important to locate the vehicle on a flat surface, preferably a concrete driveway, to avoid damaging the surface with spilled fuel.
When dealing with stubborn bolts, an impact driver is often the best tool for the job. Alternatively, you can use an Allen key, but make sure it is the right size and snugly fits the bolt head. If the bolts are rusted, you may need to apply some penetrating oil and let it sit for a few minutes to help loosen them. Then, use a rubber mallet or hammer to gently tap the end of the Allen key in a counterclockwise direction to loosen the bolts.
If you are having difficulty accessing certain bolts, you may need to remove nearby components, such as tires or panels, to gain better access. This is especially important if you need to reach any spinning hex nuts inside the frame. In some cases, you may even need to cut through certain parts, such as the bolt head, to access hard-to-reach areas.
For particularly stubborn bolts, you may need to apply heat. This can be done with a torch, being careful not to overheat the area. Additionally, consider using a wrench to hold the bolt or nut in place while you loosen it with another tool. This technique can be useful when dealing with free-spinning nuts or bolts.
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Lower the tank and remove straps
Lowering a fuel tank and removing its straps can be a challenging task, but with the right tools and precautions, it can be done safely and efficiently. Here is a detailed guide to help you through the process:
Prepare the Vehicle and Gather Tools:
Before beginning, it is important to gather the necessary tools and equipment. Ensure you have items such as strap bolts, wrenches of various sizes, screwdrivers, a jack, jack stands, and a fire extinguisher. Locate your vehicle on a flat, level surface, preferably a concrete driveway, to avoid any accidental spills. Chock the front wheels of the car to prevent any unintended movement.
Remove Fuel and Disconnect Components:
The next step is to remove as much fuel as possible from the tank to make it lighter and easier to handle. Use a pump to extract the fuel and place it in an approved gas container. Disconnect the ground cable of your battery to prevent any sparks during the process. Then, locate the fuel tank hoses and disconnect them using a ratchet and socket. Remove the filler tube, drain plug (if applicable), and any other components that may interfere with the tank's removal.
Loosen Strap Bolts and Lower the Tank:
Now, you can begin to loosen the strap bolts that secure the fuel tank. Do not completely remove the bolts yet; loosen them just enough so that the tank is still supported but can be lowered carefully. As you finish loosening the bolts, slowly lower the fuel tank to the ground. You may use a low-profile floor jack to assist with lowering the tank, ensuring that the car is jacked up high enough to provide adequate clearance.
Remove Support Straps and Tank:
Once the fuel tank is lowered, carefully remove the support straps from around the tank. Be gentle to avoid kinking or damaging the straps. With the straps removed, you can now completely detach the tank. Depending on the vehicle and the space available, you may need to drag or pull the tank sideways to remove it from underneath the car. Always be cautious when handling the fuel tank, as even an empty tank can be heavy and cumbersome.
Safety and Precautions:
Working on a fuel tank can be dangerous, so it is essential to take the necessary precautions. Always have an assistant nearby to help with tools and to respond in case of any accidents. Ensure you are wearing the appropriate protective gear, including eye protection and gloves. Before beginning any work, confirm that you have access to the required repair parts to avoid unnecessary delays. By following these steps and staying vigilant, you can successfully lower and remove the straps of a fuel tank.
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Drag the tank out and service it
Now that you've successfully lowered your car's fuel tank, you can begin dragging it out from under the vehicle. Place a work mat, a sheet of plywood, or even a scrap piece of carpet underneath the car to lay on while working for your own comfort. This will also help protect the tank as you drag it out.
Be sure to pull the gas tank support straps out and away from the tank so that they don't interfere with moving it. They are flexible, but be careful not to kink or damage them. Depending on the make and model of your car, you may need to take the plate off the back to get the tank out.
Once the tank is out, you can begin servicing it. If the tank is contaminated with the wrong fuel, you will need to drain it. You can do this by using a fuel siphon system to pump the fuel out into a container. Make sure the container is approved for combustible materials, and never use your mouth to suck out the gas, as this is hazardous to your health and can cause fires. Alternatively, if your car has a drainage plug, you can place a pan underneath it and unscrew the plug to let the fuel drain out.
If the tank is rusty, you can try using diesel fuel and shaking the tank, or a mild solution of muratic acid to dissolve the rust. However, always exercise caution when handling combustible materials, and consider seeking professional assistance if you are uncomfortable performing any of these tasks.
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Reinstall the tank
To reinstall the fuel tank, you will need to follow the removal steps in reverse. Begin by placing the tank back underneath the car, ensuring it is correctly positioned. If you had to completely remove the tank, you may need to guide it through the opening and slide it into place. Be careful not to damage any surrounding components.
Next, secure the tank in place by tightening the strap bolts. Ensure that the bolts are securely fastened and that the tank is stable. Reconnect the fuel lines and any other disconnected components, such as the fuel pump, fuel gauge sensor, or electric wires. Make sure all connections are secure and properly fitted.
If you had to drain the fuel tank, refill it with the appropriate type and amount of fuel. Refer to your vehicle's manual for the recommended fuel type. Be cautious and avoid overfilling the tank. Once the tank is securely fastened and all connections are made, you can start the car and check for any leaks. Ensure that the fuel system is functioning properly and that there are no unusual noises or issues.
Finally, lower the vehicle if it was raised, and ensure that the tank is secure and functioning properly. Test the vehicle in a safe area to ensure optimal performance.
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Frequently asked questions
To open the gas tank, first, check for a fuel tank lever or button near the driver’s side door. If there is no button or lever, push the gas tank door inward. If the gas tank door is stuck shut, engage the manual release lever through the trunk.
You will need strap bolts, slotted and Phillips screwdrivers for hose clamps, and special tools for disconnecting fuel line fittings. Other useful items include a jack, jack stands, a pump for removing the fuel, fuel-rated containers, rags, and a fire extinguisher.
First, loosen the gas tank strap bolts and carefully lower the fuel tank to the ground. Pull the gas tank support straps out so that they do not interfere with moving the tank. Remove the tank by dragging it sideways and perform the required maintenance or repairs. Reinstall the tank by following the previous steps in reverse.
Stainless steel is a great option as it is highly resistant to corrosion and not too difficult to weld. Aluminum is another good choice as it is extremely resistant to corrosion and is 33% lighter than steel, but it is very difficult to weld.
Tank slosh is when the fuel moves around in the gas tank, which can starve the fuel pump of fuel. This can be prevented by dividing the fuel tank into sections or small cells with trap doors or small holes between them. This keeps the fuel pump pickup submerged and prevents the weight of the fuel from shifting around in the car.
