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

Replacing a fuel tank is a complex task that requires careful preparation and execution. While it may not require specialist tools, it is a big job that demands a lot of work and careful attention to safety protocols. Before starting, ensure you have the necessary equipment, including car jacks, wrenches, spanners, and a fire extinguisher. The process involves draining the old fuel tank, removing fuel lines, and carefully detaching and replacing the tank itself. It is crucial to work in a well-ventilated area due to the risk of fuel fumes, and to take pictures and notes during the process for reference when reassembling.

Characteristics of Replacing a Fuel Tank

Drain the old fuel tank

Before installing a new fuel tank, you must drain the old one. This process can be dangerous, so it is important to take safety precautions. Work in a well-ventilated area, without any open flames or sources of ignition nearby. Wear protective gear such as gloves, safety goggles, and a face mask to avoid fuel splashes and inhalation of toxic fumes.

The first step is to locate the fuel tank. This can vary depending on the vehicle, but it is usually at the rear of the vehicle or under the hood. Refer to your vehicle's owner's manual for the precise location.

Next, remove the fuel tank cap to allow air to enter the tank and facilitate the draining process. This will also prevent a vacuum from forming inside the tank, making it easier to drain.

Now, you can begin to drain the fuel. There are several methods for this, depending on your vehicle's make and model. Here are some common approaches:

• Siphoning: This is the most common method. Use a siphoning kit with a hose and a hand pump. Insert the hose into the fuel tank, ensuring it reaches the bottom. Then, use the hand pump to create suction and draw the fuel out into a container.
• Electric Fuel Pump: If your vehicle has an electric fuel pump, locate the fuel pump fuse or relay in the fuse box and remove it. Turn on the ignition (without starting the engine) to activate the fuel pump and start draining the tank. Once empty, turn off the ignition and replace the fuel pump fuse or relay.
• Gravity Drain: If you have access to a car lift or jack stands, you can use gravity to drain the tank. Position your vehicle on the lift or jack stands, locate the fuel tank drain plug, and remove it. The fuel will flow out into a container below.
• Direct Drain: Some fuel tanks have a small stop valve on the body that allows you to drain the fuel neatly. Simply loosen this valve and let the fuel run into a fuel can.
• Fuel Lines: If your car doesn't have a fuel tank valve, you can remove one of the fuel lines to drain the tank. Detach the smaller line at the bottom of the tank, which directs fuel to the engine.

Dispose of the drained fuel properly. Do not pour it down the drain or into the soil, as it can harm the environment. Take it to a hazardous waste disposal site or a recycling centre.

Once the fuel tank is empty, reinstall the fuel tank cap to prevent debris or moisture from entering. Now, you can move on to the next step of removing and replacing the old fuel tank.

Remove the fuel lines

To remove the fuel lines, you will need to locate the fuel tank, which is usually on the same side of the car as the gas filler. The fuel lines are small, removable hoses underneath the tank. Before you begin, make sure to take the necessary safety precautions as you will be working with combustible materials. Wear rubber-soled shoes and cotton clothing, and have a fire extinguisher nearby.

Once you have located the fuel lines, you will need to disconnect them from the tank. Place a pan or receptacle underneath the drainage plug to catch any fuel that may leak out. You may need to use a spanner or socket wrench to remove the plug. Be careful not to use too much force, as you could puncture the filler tube or cause other damage.

If you are having trouble removing the fuel lines, it may be because fuel is siphoning out of the tank. In this case, you can try using an air compressor to blow air into the line and break the siphon. Alternatively, you can try draining the fuel into fuel cans.

In some cases, you may need to turn the car on and off repeatedly to force the gas out of the tank and through the fuel lines. Make sure to have enough drain pans to catch all the drained fuel and avoid spilling any fuel onto the ground.

Once the fuel lines are disconnected, you can move on to removing the fuel tank.

Prepare your workspace

Before you start, make sure you have all the tools and equipment you need to replace your fuel tank. This includes:

• Car jacks
• A spanner set
• A wrench set
• Hose clamps
• A fuel can
• A fire extinguisher
• A pump for removing the fuel
• Fuel-rated containers for the removed fuel
• Rags

It is also important to work in a well-ventilated area, as fuel fumes can be dangerous. If you are working indoors, ensure there are no pilot lights or other sources of flame or sparks present.

Next, locate your vehicle on a flat surface, preferably a concrete driveway. If no other option is available, hard, compacted soil is acceptable.

Before you begin, it is also a good idea to have access to repair parts. Submersible fuel pumps are usually readily available from local auto parts suppliers, but fuel-level sensing units may require special ordering from a dealer.

Finally, get help before beginning this project. Even an empty gas tank can be heavy and difficult to manage, and it is useful to have an assistant to hand you tools and respond in case of an accident.

Remove the fuel tank straps

To remove the fuel tank straps, you will first need to ensure you have the right tools. For this step, you will need a 1/2 or 9/16 inch or 12, 13, or 14 mm open-end wrench. You will also need to ensure you have a clear workspace, preferably on a concrete driveway, as fuel spills can damage asphalt.

Once you are set up, you can begin to remove the straps. First, loosen the bolts on the straps. You will need to do this carefully, ensuring that the tank is still supported as you do so. Once the bolts are loose, carefully lower the tank further, finishing the process of loosening the bolts as you go. You may be able to use a low-profile floor jack to help lower the tank, but this depends on the height of your car jack.

Next, you can remove the straps from around the tank. Be careful not to kink or damage the straps as you do so. Once the straps are removed, you can pull the tank out from under the car.

Reinstall the new tank

Reinstalling a new fuel tank is largely a reversal of the removal process. However, there are some key points to keep in mind to ensure safety and a correct installation.

Firstly, ensure you have the correct tools for the job. You will need strap bolts, slotted and Phillips screwdrivers, and special tools for disconnecting fuel line fittings. It is also recommended to have a jack, jack stands, a pump for removing fuel, fuel-rated containers, rags, and a fire extinguisher.

Before beginning, locate your vehicle on a flat surface, preferably a concrete driveway, to avoid any damage from spilled fuel. It is also advised to have an assistant to help with tools and for safety.

Now, carefully raise the vehicle with a jack to access the brackets or straps that secure the tank. Ensure the vehicle is supported by jack stands. Disconnect the fuel tank wiring harness connector and remove the ground wire screw from the chassis if your vehicle has one.

Next, remove the fuel lines from the new tank, being careful not to kink or damage them. Wipe the filler and vent pipes with a soft towel and disconnect their tubes. You may need to lower the tank slightly to access these connections.

Unhook the filler neck by either removing the screws around it or loosening the clamp and removing the neoprene hose, depending on your vehicle. Ensure the fuel hose at the top of the tank has room to move without obstruction.

Locate the fastening system, typically two straps, and loosen the bolts. Carefully lower the tank and remove the straps so they don't interfere with the installation.

Finally, slide the new tank into place and secure it with the straps and bolts. Reattach the fuel lines, filler and vent pipes, and wiring harness connector. Ensure all connections are secure and tight to avoid leaks.

Once the new tank is installed, fill it with fuel and inspect for any drips or leaks. Ensure there are no issues before operating the vehicle.

Frequently asked questions