Fuel Tank, Removal and Refurbishment - Revision history

Ian974: Added a note regarding tightening fuel pump ring studs being tightened, I'm aware of a few leaks caused by not doing this, myself included!

2019-02-23T22:45:22Z

Added a note regarding tightening fuel pump ring studs being tightened, I'm aware of a few leaks caused by not doing this, myself included!

← Older revision		Revision as of 22:45, 23 February 2019
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	[[File:2000 (34).JPG\|thumb\|none\|Pump Removed]]		[[File:2000 (34).JPG\|thumb\|none\|Pump Removed]]

			Whenever the fuel pump is removed, ensure the 8 bolts are tightened up from inside the tank before refitting to avoid leaks.

Chopper at 10:21, 24 March 2017

2017-03-24T10:21:53Z

← Older revision		Revision as of 10:21, 24 March 2017
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	This page describes the removal of a tank and pump from an S1 Elise. It will be similar if not identical for most of the Elise based cars		This page describes the removal of a tank and pump from a RHD S1 Elise. It will be similar if not identical for most of the Elise based cars

Chopper at 10:21, 24 March 2017

2017-03-24T10:21:30Z

← Older revision		Revision as of 10:21, 24 March 2017
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	30. Think about a pump replacement if your car is high mileage. Spitfire Engineering, Eliseshop and Eliseparts all have upgraded or redesigned pumps.		30. Think about a pump replacement if your car is high mileage. Spitfire Engineering, Eliseshop and Eliseparts all have upgraded or redesigned pumps.


	31. Buy new stainless steel jubilee clips for all the rubber hose connections because being a Lotus, you know you’ll be back in here again one day…… :-(		31. Buy new stainless steel jubilee clips for all the rubber hose connections because being a Lotus, you know you’ll be back in here again one day…… :-(

Chopper at 10:19, 24 March 2017

2017-03-24T10:19:59Z

← Older revision		Revision as of 10:19, 24 March 2017
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	[[File:3000 (26).JPG\|none\|thumb\|Tank Painted]]		[[File:3000 (26).JPG\|none\|thumb\|Tank Painted]]

	24. If refurbishing the original tank, it is worth unbolting the lower ring, cleaning and resealing. ~~This~~ ring is ~~threaded~~ held onto the tank by the 8 bolts, the heads are inside the tank. The lower ring is sealed to the tank with a layer of non setting fuel resistant liquid gasket eg blue hylomar.		24. If refurbishing the original tank, it is worth unbolting the lower ring, cleaning and resealing. The holes in this lower ring are threaded and it is held onto the tank by the 8 bolts, the heads are inside the tank. The lower ring is sealed to the tank with a layer of non setting fuel resistant liquid gasket eg blue hylomar.

Chopper at 10:16, 24 March 2017

2017-03-24T10:16:06Z

← Older revision		Revision as of 10:16, 24 March 2017
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	[[File:2000 (33).JPG\|thumb\|none\|Fuel Pipe Connectors]]		[[File:2000 (33).JPG\|thumb\|none\|Fuel Pipe Connectors]]

	15. With the rubber filler pipes off and the inspection hatch open, support the centre of the tank with a trolley jack and a block of wood. Undo the 4 fixing bolts and remove.		15. With the rubber filler pipes off and the inspection hatch open, support the centre of the tank with a trolley jack and a block of wood. Undo the 4 tank fixing bolts and remove.

Chopper at 10:14, 24 March 2017

2017-03-24T10:14:04Z

← Older revision		Revision as of 10:14, 24 March 2017
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	[[File:2000 (16).JPG\|thumb\|none\|Rubber Hoses at Tank End]]		[[File:2000 (16).JPG\|thumb\|none\|Rubber Hoses at Tank End]]
	[[File:2000 (10).JPG\|thumb\|none\|Rubber Hoses at Fuel Inlet End ~~thumb~~]]		[[File:2000 (10).JPG\|thumb\|none\|Rubber Hoses at Fuel Inlet End]]


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	Although you can see these connectors, they are a complete pain in the ar*e to undo.		Although you can see these connectors, they are a complete pain in the ar*e to undo.

	Better to drop the tank a cm or two (see paragraph 14****) then go back and undo the connectors. You will have more space to get your hand through the inspection hatch without lacerating your fingers and wrist.		Better to drop the tank a cm or two (section 16) then go back and undo the connectors. You will have more space to get your hand through the inspection hatch without lacerating your fingers and wrist.

	The electrical cable has plenty of slack but be careful you do not drop the tank too far as the fuel pipe have limited amount of movement and the pipes are only semi flexible		The electrical cable has plenty of slack but be careful you do not drop the tank too far as the fuel pipe have limited amount of movement and the pipes are only semi flexible

Chopper at 12:39, 23 March 2017

2017-03-23T12:39:23Z

← Older revision		Revision as of 12:39, 23 March 2017
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	The fuel connectors require to be compressed at two points at the same time while pulling the pipe off the pump. Not a great photo but you can see the connectors in this		The fuel connectors require to be compressed at two points at the same time while pulling the pipe off the pump. Not a great photo but you can see the connectors in this

			Rotate the fuel connectors a few degrees each way to break the seal before you try to pull them off.

	[[File:2000 (33).JPG\|thumb\|none\|Fuel Pipe Connectors]]		[[File:2000 (33).JPG\|thumb\|none\|Fuel Pipe Connectors]]

Chopper at 12:34, 23 March 2017

2017-03-23T12:34:09Z

← Older revision		Revision as of 12:34, 23 March 2017
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	[[File:3000 (34).JPG\|thumb\|none\|Silicon Hoses]]		[[File:3000 (34).JPG\|thumb\|none\|Silicon Hoses]]

	28. ~~Ensure~~ the shear panel is torqued up to the correct 24Nm. The panel is an integral part of the chassis support/stiffness.		28. When refitting, the shear panel, ensure it is torqued up to the correct 24Nm. The panel is an integral part of the chassis support/stiffness.

Chopper at 12:32, 23 March 2017

2017-03-23T12:32:28Z

← Older revision		Revision as of 12:32, 23 March 2017
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	Remove the rubber filler hoses completely ie undo at the fuel filler neck as well, and only refit them after the tank has been replaced. If you just undo the lower connections to the tank, you will struggle refitting the tank and reconnecting the hoses. Space and location make it very difficult.		Remove the rubber filler hoses completely ie undo at the fuel filler neck as well, and only refit them after the tank has been replaced. If you just undo the lower connections to the tank, you will struggle refitting the tank and reconnecting the hoses. Space and location make it very difficult.

	[[File:2000 (16).JPG\|thumb\|Rubber Hoses at Tank End]]		[[File:2000 (16).JPG\|thumb\|none\|Rubber Hoses at Tank End]]
	[[File:2000 (10).JPG\|thumb\|Rubber Hoses at Fuel Inlet End thumb]]		[[File:2000 (10).JPG\|thumb\|none\|Rubber Hoses at Fuel Inlet End thumb]]


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	The fuel connectors require to be compressed at two points at the same time while pulling the pipe off the pump. Not a great photo but you can see the connectors in this		The fuel connectors require to be compressed at two points at the same time while pulling the pipe off the pump. Not a great photo but you can see the connectors in this

	[[File:2000 (33).JPG\|thumb\|Fuel Pipe Connectors]]		[[File:2000 (33).JPG\|thumb\|none\|Fuel Pipe Connectors]]

	15. With the rubber filler pipes off and the inspection hatch open, support the centre of the tank with a trolley jack and a block of wood. Undo the 4 fixing bolts and remove.		15. With the rubber filler pipes off and the inspection hatch open, support the centre of the tank with a trolley jack and a block of wood. Undo the 4 fixing bolts and remove.
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	18. When the tank is completely lowered, you can pull it sideways out from under the car. To avoid damaging paintwork, it can be slide out on a piece of cardboard/carpet etc		18. When the tank is completely lowered, you can pull it sideways out from under the car. To avoid damaging paintwork, it can be slide out on a piece of cardboard/carpet etc
	[[File:2000 (20).JPG\|thumb\|Tank Lowered]]		[[File:2000 (20).JPG\|thumb\|none\|Tank Lowered]]


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	The pump is help in compression by this ring. There are 3 springs inside the pump attempting to push the top of the pump upwards.		The pump is help in compression by this ring. There are 3 springs inside the pump attempting to push the top of the pump upwards.
	[[File:2000 (33) 2.jpg\|thumb\|Fuel Pump Mount]]		[[File:2000 (33) 2.jpg\|thumb\|none\|Fuel Pump Mount]]

	20. Remove the 8 mounting nuts by undoing them a few turns at a time rather than each one individually to allow the pump to rise evenly. One of the nuts is located under the pump outlets and requires the use of an open ended spanner initially.		20. Remove the 8 mounting nuts by undoing them a few turns at a time rather than each one individually to allow the pump to rise evenly. One of the nuts is located under the pump outlets and requires the use of an open ended spanner initially.
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	I found that my old foam sealing gasket had expanded excessively. A new gasket is available from Lotus for a few £’s		I found that my old foam sealing gasket had expanded excessively. A new gasket is available from Lotus for a few £’s
	[[File:2000 (34).JPG]]		[[File:2000 (34).JPG\|thumb\|none\|Pump Removed]]


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	22. The original tank is likely to have a lot of surface rust especially around the filler pipe area and the bottom corners.		22. The original tank is likely to have a lot of surface rust especially around the filler pipe area and the bottom corners.

	[[File:2000 (25).JPG\|thumb\|Rusty Filler Pipe Area]]		[[File:2000 (25).JPG\|thumb\|none\|Rusty Filler Pipe Area]]


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	I used a combination of angle grinder with wire brush and Deox rust remover gel (cover in cling film will prevent it drying out) then prepared and painted with POR15 Metal Ready and paint		I used a combination of angle grinder with wire brush and Deox rust remover gel (cover in cling film will prevent it drying out) then prepared and painted with POR15 Metal Ready and paint
	[[File:2000 (37).JPG\|thumb\|Tank Stripped]]		[[File:2000 (37).JPG\|none\|thumb\|Tank Stripped]]
	[[File:3000 (26).JPG\|thumb\|Tank Painted]]		[[File:3000 (26).JPG\|none\|thumb\|Tank Painted]]

	24. If refurbishing the original tank, it is worth unbolting the lower ring, cleaning and resealing. This ring is threaded held onto the tank by the 8 bolts, the heads are inside the tank. The lower ring is sealed to the tank with a layer of non setting fuel resistant liquid gasket eg blue hylomar.		24. If refurbishing the original tank, it is worth unbolting the lower ring, cleaning and resealing. This ring is threaded held onto the tank by the 8 bolts, the heads are inside the tank. The lower ring is sealed to the tank with a layer of non setting fuel resistant liquid gasket eg blue hylomar.
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	27. From within the wheel arch, fit the rubber hoses to the tank filler pipes and secure with jubilee clips, then back under the car and fully tighten the tank mounting bolts.		27. From within the wheel arch, fit the rubber hoses to the tank filler pipes and secure with jubilee clips, then back under the car and fully tighten the tank mounting bolts.
	[[File:3000 (34).JPG\|thumb\|Silicon Hoses]]		[[File:3000 (34).JPG\|thumb\|none\|Silicon Hoses]]

	28. Ensure the shear panel is torqued up to the correct 24Nm. The panel is an integral part of the chassis support/stiffness.		28. Ensure the shear panel is torqued up to the correct 24Nm. The panel is an integral part of the chassis support/stiffness.

Chopper at 12:28, 23 March 2017

2017-03-23T12:28:56Z

← Older revision		Revision as of 12:28, 23 March 2017
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	'''Word Of Warning before you start'''		'''Word Of Warning before you start'''

	*A near empty/empty fuel tank is perhaps more dangerous than a full tank as there is a far greater amount of fumes contained within therefore a greater chance of explosion. Even when empty of fuel, do not expose the tank to any source of heat, flame or spark *		*A near empty/empty fuel tank is perhaps more dangerous than a full tank as there is a far greater amount of fumes contained within therefore a greater chance of explosion. Even when empty of fuel, do not expose the tank to any source of heat, flame or spark *