Defender 300 TDI Fuel Tank Replacement

[withabix]

Old tank was leaking from 'somewhere at the top' [reason at the time unknown] and also from the fuel level/fuel lift connection [due to rusting away of the lugs], so it was time for a new tank.

Started the job this weekend - old tank is off! That was probably the dirtiest job I've done apart from Waxoyling. There were copious amounts of mud, diesel soaked mud, diesel softened Waxoyl and diesel softened Waxoyl mixed with mud. And any combination thereof.

The last person who took the tank off managed not to use a single original fixing and all of the spacers etc were missing. Fortunately I had ordered all of the original fixings as I had assumed that I would end up cutting through some of the them with the Dremel to get them off - as was the case.

Tank protector then cleaned and a generous coat of smooth black Hammerite applied. A generous coat of Hammerite was also applied to the new tank, although it is Ni-Terne coated steel, so probably didn't need it, but easier to do now than to regret it later!

The new tank was a new old-stock Spectra Industries tank (Made in Canada!) obtained from Kelly at Best British Car Parts in Langley. Kelly operates this from his house now and sells on eBay. He did have premises near Langley Bypass but there evidently wasn't enough trade...

I also cleaned and painted all steel areas of the chassis and brackets that were exposed by the removal of the tank. These had been protected recently by a generous coat of diesel (hence the need for a new tank). Nothing worse than surface weathering rust found - everything rings like a bell...Underseal to rest of chassis needs a touch-up in places, but anything accessible can wait until the tank is on.

Hammerite came with me from the UK last year - I guess you can get it here somewhere (??) but I had a couple of litre cans 'in stock'.

Inspection of the old tank indicated where the leaks were coming from - apart from the fuel gauge seal, the leak from the top was coming from the steel fuel return pipe into the tank (as suspected), which was rusted out and the top of the tank around it was very rusty so the cork gasket was probably doing nothing. The new tank came with screws, isolator washers and a rubber gasket for this location, although I did also get an OEM cork one from the UK just in case. The seam at the front of the tank looked like it had failed as well, judging by the amount of diesel on the chassis. The combination of the three leaks explains why my tank capacity was down to max 40L without leaking...

Ran out of time this weekend and waiting for the Hammerite to fully harden, so may get some progress during evening in the next week or so.

Photos attached for anyone who is interested...

[withabix]

...and the other photos:

[ANDYD]

Thanks for the info and photos, looks like its all going well. Looking forward to the final update when complete.

[withabix]

Well that was a **** of a job!

Much swearing and bruises - god knows what the neighbours thought was going in in our garage!!

Spent the evening putting the tank back on and connecting the hoses back up.

Ran out of time, so I still have to fit the fuel lift pipe/float, bolt the anti-roll bar back up, re-fit the towing hitch arms and touch-up the Hammerite.

Then of course put some diesel back in....

[Rambler]

Thanks for the helpful post and info re fitting a new tank, something I need to do in the summer. I also need a new tank so will contact the person you mentioned in Langley. If someone knows where you can get smooth Hammerite on this side of the pond I'd also be keen to buy some. Best wishes

[withabix]

I don't think Kelly has any more tanks - he is running his stock down.

His eBay page is here: http://stores.ebay.ca/bestbritishcarparts/

Check his 'Completed Listings' for items he hasn't re-listed and also contact him, as I know he has Land Rover brake discs, pads and various other things.

[withabix]

Finished. I hope.

One small drip from the bottom of the filler pipe, but that I know is due to the jubilee clip not gripping - picking up a new one for that.

My only concern is that the fuel level/lift gasket will leak, because I couldn't get the Locking Ring to rotate more than about 5mm, even though I gave it some good 'attention' with a drift. All the pictures I've seen shown it far more rotated than that, so we shall have to wait and see....

If that happens, I guess I know what I'm doing over Christmas...

[Rambler]

I appreciate the comments about Kelly, thank you.