Fuel tank repairs

Fuel tank repairs

Under no circumstances should a repair to any fuel tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods:

a. STEAMING: With the filler cap and tank unit removed, empty the tank. Steam the tank for at least two hours with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any sediment and sludge not volatized by the steam is washed out during the steaming process.

b. BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling water containing an effective alkaline degreasing agent or a detergent, with the water filling and also surrounding the tank for at least two hours.

After steaming or boiling, a signed and dated label to this effect should be attached to the tank.

Body and chassis repairs

When a body or chassis repairs involve the use of heat, all fuel pipes which run in the vicinity of the repair area must be removed, and the tank outlet plugged, BEFORE HEAT IS APPLIED. If the repair is in the vicinity of the fuel tank, the tank must be removed.

Plastic fuel pipes are particularly susceptible to heat, even at relatively low temperature, and can be melted by heat conducted from some distance away.

Fuel lines or tanks must not be removed whilst the vehicle is over an inspection pit.

QUICK FIT FUEL HOSE CONNECTORS

WARNING: Hose connections between the fuel pump outlet union and the fuel rail contain fuel under pressure, which MUST be relieved prior to disconnection of hoses. See Workshop Manual, FUEL DELIVERY SYSTEM, Repairs.