Dropping the Fuel Tank - Step by Step + Fuel tank leak

Operation Fuel Drop: Remove Tank

Well today started the day i would really get cracking into fixing all the little niggling problems i have had with the car since day 1. And the first and obvious one is the Fuel Tank Leak. So this morning i went about removing the tank. Step by Step.

1) Disconnect battery for atleast 30seconds before working.

2) Locate Service Hole


3) Remove Service Hole


4) Remove Fillerpipe Protector


5) Fuel Line which need to be disconnected


6) Fuel Inlet - I was going to remove it, but i couldn't get the door opener removed


7) Remove bolts from Inlet - This was a pain, since a few are in hard to get places. As for the torque, all the bolts were screwdriver tight.


8) Unplug the lines


9) Support the tank - Important since you don't want the tank to just fall out


10) Unbolt Fastners - Again these were tight, but spanner tight


11) Remove the Tank - the moment we ahve all be waiting for


12) Tank is out!

Glory Shots
Fueltank - What fueltank?


There it is!


Now to find that fuel leak.

The little bastard!



The reason to why i have to drop the tank in the first place.

So in that case, it wasn't a leaky gasket, so for me to drop this tank off to get fixed ill have to remove everything.

Gaskets:


All the internal stuff removed:


And some close up shots of each part:
Evap Pipe : http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/evappipe.JPG
Pump: http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/pump1.JPG
http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/pump2.JPG
Sender: http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/sender.JPG

And finally, i had to cover up the fuel filler neck, to stop the dust and stuff getting into it.
http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/covered up.JPG

And a shot of inside the tank
http://ugbox.net/~lance/GT4/Repair/Fuel Tank/Out/insidetank.JPG

And thats it, took me approximately 2 hours to do, because i was taking my time. On the difficuilty scale, i found it relatively easy. I did have about 2 litres of fuel in the tank, which i poured out. I was also surprised to find rocks in the bottom of the tank. I did have one small mishap where i have accidently bent the return line out of shape, but it is easily bent back.

And thats it for now.

Whats is weight? I want to add that info to the weight reducton thread for thse of use going to fuel cell or smaller tanks.

I just went and cleaned the tank up, firstly i topped the tank full of water, and washed the outside of it.

More detailed shots of the damage

CMS-GT4":1nh3t7g4 said:

Whats is weight? I want to add that info to the weight reducton thread for thse of use going to fuel cell or smaller tanks.

Click to expand...

I wiegh 111.5Kg, and with me holding the tank i weigh 123Kg,

So the tank, with nothing inside it, just the tank is approximately 11.5Kg

Good write up.
Are you going to have the tank repaired or replace it with another one?

nice write up. thanks for that.

if it is possable do you mind having a look under your car for some tow hitch mounts and if there are any could you take some pics of them. i have be told by some people there are some and others there are none.

thanks again
roger

Great Thread.

This should be a STICKY!

Hey guys thanks for the input.

As for the tank, i took it to a radiator shop who are fixing it up for me now, Should be ready tommorrow.

Although i have hit another hitch, i can only get 3 of the 4 gaskets, as toyota don't know which gasket fits the sender hole. So i might have to reuse it. Also the evap hole gasket is $44AUD what a bloody rip off, i might be re-using that as well.

As for the tow hitches ill go have another look.

As for tow points, i can't see anything definate, but there are 2 holes on each side of the main chassis which would allow for mounting.

thanks for that. ill climb under my car and have another look.

roger

Think its possible to pull the fuel pump out without dropping the tank? Or is dropping the tank just less of a hassle of maneuvering and squeezing things out.

with the alltrac/gt4 it is impossible to pull the fuel tank out without dropping the tank. The service hole in the top of the chassis is only for the sender pipe.

So unfortionately, there isn't an wasy way to do it.

Thanks for the reply... Just wanted to see if it was possible or not.

Great instructions though... very detailed.