Mercedes Mullins
Removing the fuel tank from a classic Mini is not a common task, but it may be necessary if the bottom of the tank has rusted out due to the car being left standing for years. The first step in removing the fuel tank is to drain the fuel. This can be done by driving the car until it is almost out of fuel, or by using a pump to siphon the fuel into a container. Once the fuel is drained, the battery should be disconnected and the fuel quantity sender wire terminals removed. The tank can then be loosened and removed, taking care to collect any remaining fuel with a towel. It is also recommended to renew the filler neck gasket and protect the underside of the strap to prevent chaffing.
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What You'll Learn
Disconnect the battery
Disconnecting and removing the battery is an important first step in removing the fuel tank from a classic Mini. This is because you will be working with fuel and electricity, which can be a dangerous combination if proper precautions are not taken.
Before disconnecting the battery, it is recommended to drive the car until it is almost out of fuel. This will reduce the risk of fuel spillage and make the fuel tank lighter and easier to handle. Once the car is low on fuel, park it on a level surface, engage the parking brake, and turn off the engine.
Now, locate the battery. It is usually found in the engine bay, often in a corner or against a wall to protect it from the elements. The battery will be held in place by a bracket or clamp, and the negative and positive terminals will be connected to the car's electrical system.
To disconnect the battery, start by locating the negative terminal, which will be marked with a '-' symbol or a black cover. Loosen the nut or bolt that secures the negative cable to the terminal using a suitable wrench or socket. Do not allow the wrench or socket to touch any other metal parts of the car, as this could cause a short circuit. Once loose, carefully remove the cable from the terminal. You may need to wiggle it gently to detach it. Cover the terminal with a piece of tape or a plastic bag to prevent anything from falling on it.
Next, locate the positive terminal, marked with a '+' symbol or a red cover. Again, loosen the nut or bolt securing the positive cable and carefully remove the cable. Ensure that the positive terminal is also covered to prevent any accidental contact. With both cables disconnected, you can now remove the battery by lifting it out of its bracket or clamp. Place the battery in a safe location, away from sparks or flames, and ensure that it is properly secured so that it does not tip over.
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Drain the tank
To drain the tank of your classic Mini, start by driving the car until it is almost out of fuel. Disconnect the battery and remove the fuel quantity sender wire terminals. If the car is not drivable, you can skip this step and buy a cheap fuel pump and siphon pump to suck out the remaining fuel into a container. You can also use a hose and copper pipe to move the fuel into a container.
Next, clamp the rubber hose coming from the tank, and cut the hose. Place the hose into a container and release the clamp. You can also try clamping the hose and removing it from the line under the car, catching any spilled fuel in a container.
Then, remove the bolt towards the boot lid on the tank strap and pull the two connectors off the sender. Remove the petrol cap and the tank strap. Finally, remove the tank from the boot and replace the cap.
It is important to note that the fuel tank of a classic Mini rarely needs to be removed or replaced. The main reason for removal is usually because the bottom of the tank has rusted out due to the car being left standing for years. Regular checks and flushing of the tank are recommended to prevent this.
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Remove the fuel quantity sender wire terminals
To remove the fuel quantity sender wire terminals from your classic Mini, you should first try to drive the car until it is almost out of fuel. This will make the process of removing the fuel tank safer and easier. Once the car is almost empty, disconnect the battery to ensure that there is no power running through the vehicle. It is also recommended to remove the battery from the vehicle if possible, to avoid any accidental contact or spillage.
Next, you will need to remove the fuel quantity sender wire terminals. These terminals are located on the fuel sender, which is usually found on the side of the fuel tank. The exact location of the fuel sender and wire terminals may vary depending on the model and year of your Mini, so it is important to refer to your owner's manual or seek advice from a qualified mechanic if you are unsure.
To remove the wire terminals, you will need to carefully disconnect them from the fuel sender. Before beginning this step, it is recommended to take photos of the wiring configuration and label all wires, connectors, and components. This will ensure that you can properly reconnect the wires during the reassembly process. Once you have disconnected the wires, set them aside in a safe place to avoid any damage or misplacement.
After removing the wire terminals, you can proceed with the next steps of removing the fuel tank, such as loosening the tank strap and carefully removing the tank from the vehicle. Remember to place a container under the fuel tank to catch any remaining fuel or spills during this process.
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Loosen the tank strap
It is important to note that the process may vary slightly depending on the model of the classic Mini and the type of fuel tank it has. For example, the securing strap for the early 5.5-gallon tank goes over the top and is almost hidden from view, while the later 7.5-gallon tank is held in by a diagonal strap bolting into a bracket welded to the boot floor.
Before loosening the tank strap, it is crucial to ensure that the fuel tank is drained and that the battery is disconnected. This will help ensure a safer and more effective removal process.
Additionally, it is recommended to take photos and label all the nuts, bolts, and fixings during the removal process. This will make it easier to reassemble the fuel tank correctly and identify any parts that may need to be replaced.
By following these steps and taking the necessary precautions, you can effectively loosen the tank strap and remove the fuel tank from your classic Mini.
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Remove the tank
Removing the fuel tank from a classic Mini is usually done because the bottom of the tank has rusted out. This often happens if a Mini has been left standing for years, as water droplets in the fuel can sometimes rust the tank right through.
Before removing the tank, it must first be drained. If the Mini is drivable, the best way to do this is to drive the car until it is almost out of fuel. If the car is not drivable, you can use a pump to suck out the remaining fuel into a container. You can get a cheap fuel pump off eBay for around £7. You can also siphon the fuel out, but it is difficult to get the last litre or so out of the tank.
Once the tank is drained, disconnect the battery and remove the fuel quantity sender wire terminals. Clamp the rubber hose coming from the tank and remove it from the line under the car, catching any spilled fuel in a container. Then, remove the bolt holding the tank strap and slide the tank out.
If you are removing a 7.5-gallon tank, you will also need to remove the bolt towards the boot lid on the tank strap and pull the two connectors off the sender.
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Frequently asked questions
First, if possible, drive the car until it's almost out of fuel. Disconnect and remove the battery, and remove the fuel quantity sender wire terminals. If you can't drive the car, buy a cheap fuel pump and use it to suck out the remaining fuel into a container. Then, loosen the tank strap and remove the tank.
You'll need a cheap fuel pump, a spare disposable fuel filter, some hose, and a container to collect the fuel. You may also need a copper fuel pipe and a siphon pump.
Make sure to disconnect the battery and remove it before you start. Also, take lots of photos of how things are so that you can refer back to them when you rebuild the car. Keep and label all the nuts, bolts, and fixings, even if they're worn or rusty.
