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940 Fuel Tank Replacement

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Old Aug 9th, 2009, 16:10   #1
lamyewchoy
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Last Online: Aug 10th, 2020 16:26
Join Date: Mar 2009
Location: Kuala Lumpur
Default 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
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Old Aug 10th, 2009, 03:12   #2
lamyewchoy
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Last Online: Aug 10th, 2020 16:26
Join Date: Mar 2009
Location: Kuala Lumpur
Default Fuel Tank Replacement

1. This is the new tank
1Fuel Tank - 940 - 090809.JPG

2. This is the part no
2Fuel Tank PN - 940 - 090809.JPG

3. This is the internal view
3Fuel Tank - inside view - 940 - 090809.JPG

4. Remove Battery -ve Terminal
4Fuel Tank replacement - 940 - remove batt - 090809.JPG

5. Gain Access to the fuel pump by removing the rear carpets and remove the fuel pump compartment cover.
5Fuel Tank replacement - 940 - access fuel pump - 090809.JPG

6. Remove all hoses connected to the pump housing and another hose to the tank.
6Fuel Tank replacement - 940 - remove pump hoses - 090809.JPG

7. Jack Up car. Support the axle so that the suspension is not relaxed, to give enough room to remove the tank.
8Fuel Tank replacement - 940 - jack up - 090809.JPG

8. Support Tank from below
7Fuel Tank replacement - 940 - support tank - 090809.JPG

9.Remove the front bracketing.
9Fuel Tank replacement - 940 - remove front brkt - 090809.JPG

10. Remove the rear bracketing and the bracket itself for easier removal
91Fuel Tank replacement - 940 - remove rear brkt - 090809.JPG

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.
92Fuel Tank replacement - 940 - lower tank - 090809.JPG

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.
93Fuel Tank replacement - 940 - tank removed - 090809.JPG

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.
94Fuel Tank replacement - 940 - new tank entry - 090809.JPG
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Old Aug 11th, 2009, 03:15   #3
lamyewchoy
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Last Online: Aug 10th, 2020 16:26
Join Date: Mar 2009
Location: Kuala Lumpur
Default

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.
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