Wednesday 18th July 2012
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Replacing a fuel tank is quite a lengthy process and will require a few safety procedures are you will be working around fuel. You should wear safety goggles and have a fire extinguisher handy.

Estimated time: 3-4 hours                      Difficulty: Medium

You will need a screwdriver, socket set and pair of pliers for this job. You will also need a hammer and chisel. As you will be draining the fuel from the old fuel tank you will need some hose to extract the fuel into the new tank.

Step 1

Begin by spraying some WD-40 onto the bolts on the strap that hold up the fuel tank and unscrew the screw holding the clamp onto the fuel hose. Once you’ve removed the clamp, disconnect the fuel hose from the vehicle; disconnect any other wires or connections going to the fuel tank.

Step 2

You will need to disconnect the fuel lines to the fuel filter, but be careful as some fuel may spill out here, so get something to catch the fuel. You will also need to remove the bolts on the heat plate between the exhaust and tank so you can remove the tank from the vehicle.

Step 3

You will need to prop up the fuel tank as you prepare to remove the bolts for the strap holding up the tank. Once you have removed the strap, take the fuel tank off and place it on the floor. You will need to remove the fuel pump from the old fuel tank and place it in the new fuel tank.

Step 4

This is done by disconnecting any harnesses, wires or connections to the locking ring. Get a hammer and chisel and start moving the locking ring to open this up. Once unlocked the locking ring will spring up so you can pull the pump out from the old fuel tank.

Fitting a new fuel tank

Replace the o-ring onto the new fuel tank and put the pump inside the hole at the top of the fuel tank, locking the locking ring back in place. Re-connect all connections to the pump and prop the new fuel tank into position using a jack.

Step 6

Bolt the strap back over the tank, connect the fuel lines to the fuel filter and connect the hoses to the new fuel tank. Connect all electrical connections and bolts, ensuring everything is tightly in place. Bolt the heat plate back in place. Make sure everything is connected again to its proper place.

Step 7

Now you can siphon the fuel from the old fuel tank to the new fuel tank. Insert the hose into the old tank at one end and suck through the hose until fuel starts coming through the other end of the hose. Place this end in the new tank until all the fuel is drained into the new tank.

Step 8

Time to test that it’s all working. Turn the key in the ignition until the vehicle starts up.

And Finally...

Check underneath the vehicle for any leaks. If everything is good then the tank has been successfully installed.