Hi All,
I had a second hand fuel tank installed last year by my usual garage. (I supplied the tank). If I filled the tank to the top it over ran so I have just been half filling it. I assumed that the seal wasn't on correctly or just needed replacing so I bought a new one. I took the cover off today to find that the garage had sheared two of the fuel pump mounting studs and so they were missing. No surprise it's leaking then.
What are my options if indeed I have any at all? I'd wondered about taking the tank out, letting it dry out for a few days and then trying to drill holes to put some nuts through from inside, I know they'd need securing somehow, epoxy maybe.
Is there an alternative or do I just get a new tank? I had it done at the garage as I thought removing the exhaust would be a right PITA. In fairness to him one of the studs was slightly bent but all rest were okay so I can't imagine how he did this. It was actually a very good tank and I assume it was one that had been replaced after the recall.
Before anyone says it, yes I am aware of the dangers in trying to drill a fuel tank.

Cheers,
Ian.

you could drill a hole through where its snapped and take the insert for the fuel level out and bolt it but that will leak

BUT

you do have the right as a customer for the garage to fix the fuel tank as they have incorrectly fitted and damaged it, which is what i would do first

Ash

I did the same thing with a spanking new tank:
https://www.fiatforum.com/cinquecento-seicento/236944-i-think-ive-just-buggered-new-fuel-tank.html

TBH tho mines not had any problems, the pump sucks fuel causing a negative pressure in the tank, I'd be tempted to clean the surface up and change the seal anyway. but are you sure that the leak is coming from there? do you know that the new tank is 100% sealed?

when you tighten the nuts up after changing the seal, do it CAREFULLY they dont take much to snap them.

Thanks for the replies chaps.
@ Benjammo. Yes, that looks exactly like mine. It's kind of comforting to know that it can happen even on a new tank, lol.
Yes, I'm pretty certain the leak is from there. When it first happened I had filled right to the top and the car absolutely stank. I looked underneath and it was coming from over the top of the tank, running everywhere not just in one place. Could be somewhere else I suppose but I daren't fill it to the top to find out!
Yes, I know it should have gone back to the garage but I know him and he's normally really good and he is VERY kind to me about the handbrake at MOT time.
Not sure what to do now. I have a couple of long journeys coming up and could have done with getting the tank filled to the top.

Ian.

You might try something like hylomar round the seal, but, if it still leaks, the drilling out (and re-tapping the hole) and using a longer bolt rather than a stud trick should do it.

Remove the tank, wash it out, bung up all the holes and fill completely with water (or inert gas) to remove explosion risk.

fingers99 said:

drilling out (and re-tapping the hole) and using a longer bolt rather than a stud trick should do it.

Click to expand...

Aah, so the studs are screwed in are they? I hadn't realised that. I had assumed they were welded in. Interesting. There is a few mm left so I may be able to get them out although I won't bank on it.

I'm not sure (never having broken one!) -- but, if you can drill out and tap, finally use some studseal on the bolt inserted from the tank out) you've a fix that's almost as secure as a welded in stud (which I suspect is the case).

i have a similar problem but i don't think it's the tank. it looks more like the pipe which is connected to the tank is leaking. when full it's absolutely pissing out everywhere, must be tickeling around the tank but from the looking at it from inside the car there was only one place high enough for it to be coming out from

I'm beginning to wonder myself now if I'm right about it being the pump gasket. I may get some petrol in a can and fill it slowly until it leaks. Whatever it is I hope I don't have to take the tank out!

Ian.

Has the breather been properly fitted?

Cheers

D

I don't know TBH. I'll have a crawl under one day and have a look. But it is very hard to breathe in the car when it's leaking!

Have a feel around the tank and make sure all the breathers including the filler breather are attached.

Might be worth dropping the tank to check.

Cheers

D