How to Install a New Fuel Tank

Fuel tank is one of the main parts of any automobile. It stores fuel and make it available for combustion process. At times fuel tanks develop leaks or get punctured or get cracks. The fuel begins to leak from the tank that is not only the waste of fuel but also a big threat to your safety. It should be replaced at first instance.

Required Items

• Fire extinguisher
• Wrench
• Sockets
• Floor jack
• Fuel line
• Hose clamps
• New fuel tank
• Hose clamps
• Container

Instructions

• You have to drain all the fuel out of the tank first. Take a proper container to keep the drained fuel safe. Before that find the drain valve at the bottom of the fuel tank. Open the drain valve and let all the fuel drain out completely.
• If your tank does not contain any drain valve then disconnect any of the fuel line by removing the clamp. Fuel lines may attach to fuel filter, fuel pump or a hard fuel line. You can remove any one of it. Drain the fuel out completely.
• Take a clean empty can to store the fuel. You can refill this fuel later in your new tank.
• Now detach all the remaining fuel lines connected to fuel tank. Starting from the supply line, which supplies fuel to the engine.
• Fill tube line comes from the gas fill entry point. Other than that there is a vent line that helps to release the pressure during change in fuel level.
• Detach all these lines from the fuel tank. Note that you have to remember the position and setup of the hoses so that you will connect them accurately at the end. You can take a photo also for your convenience.
• Inspect your engine or tank area to see if you can remove fuel tank with rear suspension in place or not. In latter case, you have to drop the suspension. Some vehicles have a single beam in their rear. In front wheel vehicles this is called a beam suspension and in rear wheel vehicles, it is an axle with rear differential.
• Dismiss the bottom fitting on the rear shock absorbers. Hold the suspension and pull it down and separate to the dangling shocks.
• Take a floor jack and support the suspension beam at the center. Jack will help you to lower the heavy parts easily.
• Disconnect the bolts of lower shock mount, to drop the rear suspension for the sake of removing fuel tank.
• To avoid any damage to the braking system, dismiss the rear brakes.
• Detach the large nuts connecting the rear beam to the car’s frame. Lower the rear suspension with the help of floor jack.
• Fuel tank is supported by couple of metal straps. Loosen the nuts at one end of the strap holding the fuel tank. It will fall down; later loosen the nuts from other end. Pull those straps down the tank will automatically falls down.
• Take a new fuel tank and install it in a same way you remove the tank. Remember you have to reconnect all the hoses in a perfect order, otherwise it may damage to your engine or other components.

Precautions

• Choose a clean and well-organized place to work.
• Make sure that there is no inflammable material nearby. A small spark can be severe.
• Well-ventilated area is good for work. Always keep a fire extinguisher for safety.

Damage fuel tank is extremely dangerous. It can catch fire at anytime. So, it is better to replace it before it is too late.