Made a start on the fuel filler neck replacement and I'm going to need a few new parts in order to put it all back together.
The tank straps are rusty but serviceable but I have sheared all of the tank cover retaining bolts - they hold the plastic cover over the tank and fasten into the tank straps. I've not investigated too much yet but I have 2 options:
1) drill out/remove the sheared bolts from the tank straps, clean up the rust, protect and find some spare 10mm bolts to hold on the cover.
2) Buy new straps and fixings.
I know what the cheapest option is! I will take a closer look at the straps first and make sure I'm happy with the state of them before I reuse.
Once I'd got the tank off which wasn't actually too much of an ordeal I then set about trying to remove the filler pipe itself - this thing is in a right state.....proper corroded.
I chiselled off as much of the rust I could to get access to the small 8mm bolt heads. Surprisingly, 4 of the 7 bolts came out without issue. Seems is just massive surface rust ratehr than the threads being rusted or damaged.
2 bolts I had to get a good pair of pliers on to remove (after filing some straighter edges onto the bolt heads) and 1 I cannot remove.
I have an 8mm Irwin bolt extractor socket arriving this week so I can hopefully remove this final bolt.
I've new 8mm bolts already to fit along with a new filler pipe.
In case anyone is wondering, fuel tank removal steps are as follows:
* Lift boot/trunk carpet and disconnect 2x fuel pump/sender connectors.
* Remove/lift boot plastic (LHS) and move auto-aerial motor assembly out of the way so you can reach....
* Fuel flap release mechanism - un-bolt by reaching into boot area with one hand to hold onto the release mechanism whilst you loosen the bolt inside the fuel flap.
* Remove the 4 screws holding the surround to the top of the fuel filler pipe (inside the fuel filler door).
Under the car:
* Jack up rear of car.
* Remove LHS rear wheel and wheel trim - 2x bolts securing.
* Remove 6x 10mm bolts holding on the plastic fuel tank cover. 5 bolt into the tank straps and a 6th on the corner of the tank, nearest the filler neck - access from the wheel well.
* Disconnect 3x lines going into the fuel tank. 2 are clips and 1 is union - catch fuel.
* For me, the straps are rusty so I disconnected them by removing them direct from the chassis, nearest the diff. Each strap is held on by 2 bolts which you can reach up to behind the rear of the diff.
* Supported with a length of wood to spread the load, place a jack under the tank at this stage to take the weight.
* Remove the other ends of the tank straps (nearest the rear of the car) - 2 bolts on each strap.
* Tank can now be lowered down on the jack. May need a little big of wiggling to get it to come down without fouling the pipes and the filler neck.