Tips for fuel tank replacement

[aevansgatech]

I sprung for a new fuel tank, and will likely fix/patch/coat the old one once it's out. Any tips or procedures I should follow during the swap?

[bluespider262]

Go to harbor freight and get one of those handpump siphons for 5-10$. Makes it really simple to empty the tank. It really isn't that difficult beyond getting the fuel out. I still had crimp fittings on my 3 vapor recovery hoses on the left side but was easily able to push the hoses off and back on w/out removing/destroying those. It really isn't a bad job - just get the gas out first.

I would also be prepared to touch up any surface rust etc. on the trunk pan around the tank. I had a little bit of surface rust in spots when I removed mine.

If you are fixing to pull the rear bumper, or do anything with that, now is the time because you will have access to that side bolt w/out having to cut it.

[azruss]

If your big filler hose is old, it will be hard as a rock. I would replace it while youre in there.

[aevansgatech]

If your big filler hose is old, it will be hard as a rock. I would replace it while youre in there.

Haven't been under there to look, but isn't the filler neck assembly all metal?

[76was124]

Haven't been under there to look, but isn't the filler neck assembly all metal?

It's a rubber elbow between the metal fill tube and the tank. I would replace it for sure, as well as the other hoses if they have never been replaced. There are some good forum posts on alternate tubing for the vent lines you can read. Also there is a two way valve between the tank and fuel pump that is worth giving a good cleaning or replacement. If you hear air sucking into your fuel tank when you remove your gas cap after running the engine, the two-way valve is likely gummed up. Otherwise the fuel filter and any rubber fuel lines underneath as well.

I also used rubber weather stripping on the bottom of the tank flange to give a better water tight seal.

Edited: Found one of the links:
http://www.fiatspider.com/f08/viewtopic ... tank+hoses

[aevansgatech]

Mission accomplished! Full tank and no drips

I replaced the 3 vent lines to the check valve as well. Had to leave the elbow for another time