Mercedes Mullins
Replacing a car fuel tank is a big job, but it's relatively simple and usually doesn't require specialist tools. The first step is to drain the fuel from the old tank, either by using a small stop valve or by removing one of the fuel lines. You'll then need to remove the metal straps and bolts holding the tank in place, before putting the new tank in position and reattaching the straps and bolts. Finally, you'll need to reconnect the fuel lines and fill the car up with fuel, checking for any leaks.
| Characteristics | Values |
|---|---|
| First step | Drain the fuel out of the old tank |
| Tools | No specialist tools needed |
| Drain plug | Most cars will have a drain plug on the bottom of the tank |
| Fuel lines | There should be two fuel lines going into the tank |
| Metal straps | Remove the two metal straps held in place by two metal bolts |
| Sub-frame | Lower the sub-frame from the car |
| Hoses | Disconnect the remaining hoses from the evap system |
| Final step | Fill the car up and inspect the tank to check there are no drips or leaks from around the pipes and lines |
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What You'll Learn
Draining the fuel from the old tank
Most cars will have a drain plug on the bottom of the tank that you can undo. Do not drill a hole in it – drilling metal has the potential to create sparks, which could be dangerous. Even when the tank is completely drained, it’s still going to reek of fuel. As such, changing the tank is a job to be done somewhere well ventilated, not in your integral garage with the door closed. Fuel fumes can lead you to pass out, which could cause injury. In the case of petrol, the vapour is extremely flammable.
Once the fuel has been drained, you will need to remove the two metal straps that are held in place by two metal bolts. This is a relatively easy process and will allow you to put the new tank into place, which can then be attached to the car by the same straps.
Finally, you’ll want to go through the removal steps in reverse to ensure that the lines are in place, before filling the car up with the appropriate fuel. When you have replaced the tank, fill the car up and inspect the tank to check there are no drips or leaks from around the pipes and lines.
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Removing the metal straps and bolts
Once you have drained the fuel from the tank, you can start to remove the metal straps and bolts. This is a relatively easy process. First, leave the remaining two large bolts in place and get a jack to support the sub-frame on the cross member underneath the tank. Then, remove the last two bolts. Now you can start lowering the sub-frame from the car. Wiggle it as you lower it, because it tends to hang up on the front body to sub-frame bushings and come down crooked if you don't.
Next, you will need to remove the two metal straps that are held in place by two metal bolts. This will allow you to put the new tank into place, which can then be attached to the car by the same straps.
Finally, go through the removal steps in reverse to ensure that the lines are in place. Before filling the car up with the appropriate fuel, inspect the tank to check there are no drips or leaks from around the pipes and lines.
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Putting the new tank in place
After the new tank is in place, you will need to go through the removal steps in reverse to ensure that the lines are in place. Then, fill the car up with the appropriate fuel. Once the tank is filled, inspect it to check there are no drips or leaks from around the pipes and lines.
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Reattaching the fuel lines
First, you'll need to drain the fuel out of the old tank. Many tanks have a small stop valve on the body of the part that allows you to neatly drain all of the fuel. If this is the case, simply loosen the valve and let the fuel run out into the fuel can. However, if your car has no fuel tank valve, you’ll have to remove one of the fuel lines and use it to drain the tank of fuel. 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 of the tank is used for filling the tank.
Once the tank is drained, you'll need to remove the two metal straps that are held in place by two metal bolts. This is a relatively easy process and will allow you to put the new tank into place, which can then be attached to the car by the same straps.
Finally, you'll want to go through the removal steps in reverse to ensure that the lines are in place. Remember to go slow and, as soon as you can reach, disconnect the remaining hoses from the evap system and get all of the hoses out of the plastic clips before dropping the tank right down. When you have replaced the tank, fill the car up and inspect the tank to check there are no drips or leaks from around the pipes and lines.
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Checking for leaks
When replacing a car fuel tank, it is important to check for leaks. This is a big job, and there is a degree of danger when dealing with a fuel tank, as fuel has a propensity to ignite.
First, drain the fuel out of the old tank. Many tanks have a small stop valve on the body of the part that allows you to neatly drain all of the fuel. If this is the case, simply loosen the valve and let the fuel run out into the fuel can. However, if your car has no fuel tank valve, you will have to remove one of the fuel lines and use it to drain the tank of fuel. 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 of the tank is used for filling the tank.
Once the tank is drained, it will still smell of fuel. Therefore, it is important to change the tank somewhere well-ventilated, not in an integral garage with the door closed. Fuel fumes can lead to fainting, and in the case of petrol, the vapour is extremely flammable.
After you have replaced the tank, fill the car up and inspect the tank to check for drips or leaks from around the pipes and lines. You will need to remove the two metal straps that are held in place by two metal bolts. This will allow you to put the new tank into place, which can then be attached to the car by the same straps.
Finally, go through the removal steps in reverse to ensure that the lines are in place. Remember to go slowly and disconnect the remaining hoses from the evap system. Get all of the hoses out of the plastic clips before dropping the tank right down.
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Frequently asked questions
Many tanks have a small stop valve on the body of the part that allows you to neatly drain all of the fuel. Simply loosen the valve and let the fuel run out into the fuel can. If your car has no fuel tank valve, you’ll have to remove one of the fuel lines and use it to drain the tank of fuel.
You’ll need to remove the two metal straps that are held in place by two metal bolts. This is a relatively easy process and will allow you to put the new tank into place, which can then be attached to the car by the same straps.
Go through the removal steps in reverse to ensure that the lines are in place, before filling the car up with the appropriate fuel. When you have replaced the tank, fill the car up and inspect the tank to check there are no drips or leaks from around the pipes and lines.
Changing the tank is a job to be done somewhere well-ventilated, not in your integral garage with the door closed. Fuel fumes can lead you to pass out, which could cause injury. In the case of petrol, the vapour is extremely flammable.
