Sylvie Willis
Fuel tanks are essential components of a vehicle, holding the fuel that allows the car to run. While replacing a fuel tank is a big job, it is relatively simple and does not usually require specialist tools. However, it should be noted that fuel is highly flammable, so extra care must be taken when performing this task. The first signs that your fuel tank may need replacing include puddles of fuel under your car after it has been parked or higher-than-usual fuel consumption. If you suspect a leak, an inspection of the tank should be carried out to confirm.
When you should get a new fuel tank
| Characteristics | Values |
|---|---|
| Fuel tank leaks | Replace the tank if there are puddles of fuel around your car after it has been parked |
| Fuel consumption | If your car is consuming more fuel than usual, it may be time to replace the tank |
| Tank inspection | If an inspection reveals a leak or drip, the tank should be replaced |
| Tank damage | If the tank has been punctured or damaged, it will need to be replaced |
| Warranty expiration | Consider replacing the tank if its warranty has expired (typically after 30 years) |
| Incompatible fuels | If using modern fuels with older tanks, replace the tank if it is not compatible with the fuel type |
| Safety | Replace metal tanks in older cars with plastic tanks to prevent corrosion and increase safety |
| Ventilation | Ensure adequate ventilation when replacing the tank to mitigate the risk of ignition |
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What You'll Learn
Fuel leaks or puddles under the car
If you notice a puddle of liquid underneath your car, it could be a fuel leak. Fuel leaks usually occur because there is a crack or hole in the fuel tank somewhere. The first sign of a fuel tank issue will be puddles of fuel around your car after it has been parked. You may also notice a strong, distinctive smell of petrol or diesel, higher fuel consumption than normal, a hissing sound, or a fall in fuel efficiency. If you can, inspect the fuel tank and fuel lines for any damage. A metallic smell may indicate corrosion on the fuel tank or fuel lines, which could lead to a fuel leak.
However, not all puddles under your car are cause for concern. If your car is leaking a clear, water-like liquid, it is probably just water. This could be condensation from the air conditioning unit or exhaust, or it could be from your windscreen washers. A clear liquid could also be coolant, which will likely have a coloured tinge and an odour.
If the puddle is not clear, you may have a more serious issue. A brownish or black liquid is likely to be engine oil, which could be caused by gaskets drying out. An amber or black liquid could also be engine oil, which will feel slick and hard to get off your fingers. Power steering fluid is red to light brown and commonly drips from the front of your car.
If you notice a fuel leak, do not drive your vehicle. Petrol and diesel are highly flammable, and you will waste a lot of fuel. If you have the required technical knowledge, you can inspect the fuel tank and fuel lines for any damage. Unless you have substantial mechanical know-how, the safest option is to take your car to a garage for repairs.
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Higher fuel consumption than usual
If you are experiencing higher fuel consumption than usual, there are several factors to consider that may help you improve fuel efficiency and maximise your mileage. Firstly, it is important to check your tyre pressure regularly. Underinflated tyres can significantly impact fuel economy, even causing a reduction of up to 2.5% in some cases. Therefore, ensuring your tyres are inflated to the recommended pressure is crucial.
Another factor that can influence fuel consumption is the weight of your vehicle. Removing any unnecessary tools, equipment, passengers, or stock can help reduce weight and improve fuel efficiency. Similarly, removing roof racks and carriers when not in use can also enhance aerodynamics and reduce drag, leading to better fuel economy. Additionally, the number of passengers or cargo weight can also impact fuel consumption, so removing any unnecessary items can help improve mileage.
Your driving habits can also play a significant role in fuel efficiency. Obeying speed limits and maintaining a steady speed can positively impact fuel consumption. For example, reducing your speed from 65 mph to 55 mph can result in noticeable improvements, such as an increase of 6 mpg in a Nissan Altima and 8 mpg in a Toyota RAV4. Therefore, adjusting your driving speed and maintaining a consistent pace can help maximise your mileage.
Furthermore, choosing the right fuel and filling up your tank can also impact fuel efficiency. While it may be tempting to opt for cheaper options, investing in good-quality fuel, such as Top Tier gas, can benefit your vehicle in the long run. Top Tier gas is held to a higher standard and is offered by brands like Chevron, Costco, Exxon, Mobil, and Shell. Using such fuel can help keep your engine clean and deposit-free. Additionally, filling your tank completely can reduce the space for condensation to form, which can cause performance issues and reduce fuel efficiency. While a full tank may slightly increase your vehicle's weight, the difference is negligible, and you will benefit from reduced trips to the petrol station, saving both time and mileage.
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Replacing the fuel tank is a big job
Firstly, you need to drain the tank completely. Then check it and do it again. And just to be sure, do it again. Store the fuel in a proper container, too – not old jars or ice cream tubs. Most cars will have a drain plug on the bottom of the tank that you can undo. If you struggle to get it off, do NOT try to drill a hole in it – drilling metal will heat up the metal and cause sparks, which vastly increases the risk of you being set on fire.
Secondly, 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. But more than that, in the case of petrol the vapour is extremely flammable. One errant spark and it’s game over. So please spend a few dollars and have a fire extinguisher to hand. And we mean right by your side, not in an understairs cupboard. It will stop a moment of panic from becoming a car-destroying inferno.
Thirdly, you may need to drop the suspension, a driveshaft might need to come out, you'll have to unclip all the fuel lines, the list goes on. You’re going to have a million different nuts and bolts off the car, so do yourself a favour and bag them up and write on the bag what they’re for. Take pictures of things before you take them off so you know how and where they should go. You’ll be glad you did.
Finally, rust loves a bit of osmosis, so if you put rusty bits tight against the new tank’s metal, you’re inviting it in. As for the other parts – this is your fuel system, not only is it important, it’s also extremely dangerous. You’ve got the car apart anyway, so get new gear on there.
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No specialist tools are needed
Replacing a fuel tank is a big job, but it doesn't require any specialist tools. You will, however, need to be extra careful, as fuel is involved, and there is a degree of danger due to its propensity to ignite. It is recommended to work in a well-ventilated area and have the appropriate fire extinguisher, which would need to be a Class B extinguisher.
The first sign that your fuel tank is damaged will be puddles of fuel around your car after it has been parked. Alternatively, you may notice higher fuel consumption than normal. An inspection of the tank should visually confirm if there is a leak or drip occurring.
To replace the tank, you will first need to remove the old one. This involves removing two metal straps that are held in place by two metal bolts. This is a relatively easy process. Once the old tank is removed, you can put the new tank into place, attaching it to the car using the same straps. Then, simply go through the removal steps in reverse to ensure the lines are in place.
Finally, fill the car up and inspect the tank to check for any drips or leaks from around the pipes and lines. If there are no leaks, your car is ready to go.
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Safety precautions must be taken
Safety Precautions:
When it comes to fuel tanks, safety should always be a top priority. Whether you're dealing with a fuel tank in a boat, a vehicle, or a stationary storage tank, there are several precautions you must take to ensure your safety and prevent accidents. Here are some essential safety measures to follow:
Safe Fuel Storage:
- Use approved containers and portable fuel tanks designed for the specific type of fuel. Avoid using plastic containers as they often do not meet the safety requirements.
- Store fuel away from potential hazards, such as ignition sources, high-traffic areas, and buildings. Maintain a distance of at least 20 feet between the fuel tank and any structures.
- Avoid storing excessive amounts of flammable liquids. Limit the hose length to 50 feet during fuel transfer.
- Properly seal and secure the containers to prevent leaks and evaporation.
- Ensure the fill valve is open during the refuelling process.
- Do not overfill fuel tanks. Stop transferring fuel before it overflows.
Personal Protective Equipment (PPE):
- When handling fuel, wear appropriate PPE, including eye protection, hearing protection, hand and foot protection, and flame-resistant clothing (FRC).
- Ensure that anyone nearby, including passengers in a boat, refrains from smoking or engaging in any activities involving open flames or sparks.
Spill and Fire Precautions:
- Have spill kits readily available and set up containment systems to manage spills promptly and minimise environmental harm.
- Install fire extinguishers, fire alarms, and smoke detectors near the fuel storage area, ensuring they are easily accessible and regularly maintained.
- Post visible signage, including "No Smoking" signs, content stickers ("Diesel Fuel", "Kerosene", etc.), and National Fire Protection Association (NFPA) diamond placards.
- Develop and communicate an emergency response plan to outline the procedures in case of a fire or fuel-related incident.
Engine and Equipment Considerations:
- Before refuelling a boat, turn off the engine and all other equipment to reduce the risk of fire and manage factors that may affect the fuel.
- Ensure your fuel lines, connections, and vents are in good condition. Keep air vents and valves open for proper ventilation.
- After refuelling, reopen all closed compartments to ensure air circulation and eliminate fumes before starting the engine.
- Do not fill a boat fuel tank above 90% to prevent accidental discharge through the fuel vent.
By following these safety precautions, you can help protect yourself, your property, and the environment from potential hazards associated with fuel tanks.
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Frequently asked questions
You may notice puddles of fuel under your car after it has been parked or higher fuel consumption than normal. An inspection of the tank should confirm if there is a leak.
Replacing a fuel tank is a big job but it does not require any specialist tools or complex mechanical work. You will need to be careful as fuel is involved and take appropriate safety precautions.
You will need car jacks, a spanner set, a wrench set, hose clamps, and a fuel can.
First, you will need to remove the old tank. Then, you can put the new tank into place and attach it using the same metal straps as the old tank. Finally, go through the removal steps in reverse to ensure the lines are in place and fill the tank with fuel to check for any leaks.
