940 Fuel Tank Replacement
 

I got a leak on my fuel tank and decided to replace with a new one.


1. First is to open the rear carpets to gain access to the fuel pump.
Attachment 16555

Fuel Tank Replacement
 

1. This is the new tank
Attachment 17697

2. This is the part no
Attachment 17698

3. This is the internal view
Attachment 17699

4. Remove Battery -ve Terminal
Attachment 17700

5. Gain Access to the fuel pump by removing the rear carpets and remove the fuel pump compartment cover.
Attachment 17701

6. Remove all hoses connected to the pump housing and another hose to the tank.
Attachment 17702

7. Jack Up car. Support the axle so that the suspension is not relaxed, to give enough room to remove the tank.
Attachment 17704

8. Support Tank from below
Attachment 17703

9.Remove the front bracketing.
Attachment 17705

10. Remove the rear bracketing and the bracket itself for easier removal
Attachment 17706

11. Now you can lower the tank and try to manouver it out. Because the pump housing is still on the tank, pay attention not to damage it. The rear hand brake cable is running below the tank, so have to make sure it slides out properly. During reinstall the new tank, this step need attention as well.
Attachment 17707

12. Tank removed. Take this oppurtunity to inspect anything needs attention:
a) tidy and secure all fuel lines and pipes
b) check all rubber bushings hidden behind the tank
c) check and rectify any corrossion
d) replace any hose if necessary.
Attachment 17708

13. After everything is done, it is time to reinstall the new tank.
Of course, the pump assembly to be transfered to the new tank first.
Check also the wire connection and float housing in the pump assembly.
Attachment 17709

After completing the new tank replacement, i now left with the old tank which cracked. I plan to do a repair on it.
After much survey on other forums, i will rule out adhesive and go for spot moulding process. To do this, i have to get matching material and a hot press with controllable temperature.

Any member have tried this method?
Anyone knows the grade of HDPE of the tank?
What is the right tremperature to get a good bonding?
Hope members can assist me to do this experiment, thks.