Removing the fueltank

[Ivan141]

Guys,

I need some info on this as I will be attempting this amazing feat here in my street tomorrow. I cant find any clear guidelines in my books and I'm sure that there's some trick to getting it off neatly.. I know that it's suspended in a pair of braces, but how about the filler neck, and the fuel lines? How do lower the tank from the car? It's still half filled..(might need to lever it out of there with a tube..)
Any advice is welcome.

[1974KE25]

I always used to do this in my street and not in a workshop (but in a workshop it works out 500% better!).
Just unscrew the filler neck (three screws near the petrol cap), jack up the car as far as possible, support the tank with a jack (! put some wood between the jack and tank for support) Then loosen the nuts which keep the tank in place (front side of the two straps), don't remove them all the way! If the nuts are loose, just remove the two splines which keep the two pens in place at the back of the straps. Then you can lower the straps from the backside of the car and lowwer the supporting jack to lowwer the tank.
If you need more info, just PM me (in Dutch... )

Fuel pump broken down???

[Apolan]

eggzactly like that. and if you only have one jack, drive it up on a curb like i did..

[Jan Pedersen]

I couldn't have said it better! Just make sure it is as empty as possible and have someone to help you get it down...

[Ivan141]

I'm probably going to have to tackle the operation by myself...I hope I have enough tube left somewhere to suck a bit of petrol out of the tank first...And there's an odd chance that I'll have to buy a new jack since the one I usually use is at nohachi's place at the moment
Cant say I'm looking forward to this due to the nasty weather we have this week, but I really need to get my car running this weekend.

[1974KE25]

Just call NoHachi to bring your jack back.... And as he is there when he brings it, let him help you putting the tank back under the car.
Getting it out can be done by one person, getting it back under is much harder for one man alone...

[Ivan141]

Thanks for all the advice so far 1974KE25... My brother is actually already here, and luckily so is my jack, but I dont know if he'll be around here when the time comes to put the tank back in. He has an appointment to go work on his KE25..

[Ivan141]

Ok guys...I've run into some difficulties as usual. Although I have my jack...I dont have the right tools to get the bolts loose. One bolt is next to the panhard mount on the chassis, and can only be reached with a huge extending piece for a ratchet which I dont have. The other bolt I can sort of reach but it's very much stuck in place...both where covered in undercoating.
I only managed to get the tank a bit more empty...now it only has it's reserve left on the gauge (dont have any more jerrycans left).
I wish I had a bigger toolset over here....or better yet some airtools..

Anyone have any suggestions? I'm starting to reconsider grinding a bit of the boot floorpan out and just taking it out from the top...

[1974KE25]

Well grinding the floorpan doesn't get you any further..
But I think the problem will get fixed today with some help... :wink:

[Pugho]

I removed the tank from my AE82 yesterday, and my advice to you is to empty the tank before you try to remove it.
You have fuel injection right? In that case it is easy to empty it because you have the right tool for it already in the tank. Just loosen the return line from the fuel rail (or replace the cold start injector with a hose) and run the fuel pump by bridging the right terminals in the diagnostics plug.
My AE82 was carburetted, så it was a little harder for me. I managed to remove the filler neck and plug the thick hose from it, but the tank still had about 13-14 liters of fuel in it so it really was a pain to get it down.
This is how I emptied the tank:


Oh.. and be sure to remove the back seat and remove the cable for the fuel level gauge.. And maybe for the pump as well..