How To Change A Gas Tank
Changing a gas tank, whether due to damage, rust, or the need for a larger capacity, can seem like a daunting task. However, with the right tools, preparation, and a healthy dose of caution, it's a project many DIY enthusiasts can tackle. This guide provides a comprehensive, step-by-step approach to safely and effectively change your gas tank.
Why Changing Your Gas Tank Matters
While it might seem like a purely cosmetic or upgrade-driven decision, replacing a gas tank can be crucial for several reasons:
- Safety: A leaking or severely rusted gas tank poses a significant fire hazard. Gasoline leaks are incredibly dangerous and can ignite easily, leading to serious accidents.
- Vehicle Performance: Contaminated fuel from a rusty or damaged tank can clog fuel filters, damage fuel pumps, and negatively impact engine performance. Replacing the tank ensures a clean fuel supply.
- Legal Compliance: A leaking gas tank can violate environmental regulations and result in fines. A sound, intact tank ensures compliance.
- Preventative Maintenance: Replacing an aging gas tank, even if it doesn't show obvious signs of failure, can prevent future problems and costly repairs down the road. Rust weakens metal over time, and preventative replacement is often more economical than dealing with a catastrophic failure later.
- Upgrading Fuel Capacity: For off-roading or long-distance driving, upgrading to a larger capacity fuel tank extends range and reduces the frequency of refueling stops.
How to Choose the Right Gas Tank
Selecting the correct replacement gas tank is paramount for a successful and safe installation. Consider these factors:
Compatibility
This is the most crucial aspect. Your new tank must be compatible with your vehicle's make, model, and year. Check your vehicle's owner's manual or consult with an auto parts dealer to confirm the correct part number. Don't rely solely on visual similarities; precise fitment is essential to avoid leaks and installation issues.
Material
Gas tanks are typically made of either steel or plastic. Each material has its advantages and disadvantages:
- Steel: Steel tanks are generally more durable and resistant to physical damage. However, they are susceptible to rust, especially in environments with road salt.
- Plastic: Plastic tanks are resistant to rust and corrosion, making them a good option for areas with harsh weather. However, they may be more vulnerable to punctures or cracks from impacts.
Consider your driving environment and typical road conditions when choosing the material. If you live in an area with heavy snow and salt, a plastic tank might be the better choice.
Capacity
If you're upgrading for increased range, carefully consider the new tank's capacity. Ensure it fits within the vehicle's frame without modifications. Also, be aware that a larger tank will add weight to your vehicle, potentially affecting handling and fuel economy.
Quality and Brand Reputation
Opt for a reputable brand known for producing high-quality gas tanks. Reading online reviews and seeking recommendations from mechanics or other vehicle owners can help you make an informed decision. A cheap, poorly made tank is more likely to leak or fail prematurely, leading to further expenses and potential safety hazards.
Fuel Pump Compatibility
Modern vehicles often have the fuel pump integrated into the gas tank. If this is the case for your vehicle, ensure the replacement tank is compatible with your existing fuel pump. You might need to purchase a new fuel pump if the original is damaged or incompatible.
Step-by-Step Guide: Changing Your Gas Tank
Warning: This procedure involves working with gasoline, which is highly flammable. Take extreme precautions to prevent fires or explosions. Work in a well-ventilated area, avoid sparks or open flames, and wear appropriate safety gear.
Tools and Materials Needed:
- New gas tank
- Floor jack and jack stands
- Wrench set
- Screwdriver set
- Fuel line disconnect tool (if necessary)
- Drain pan
- Siphon or pump
- New fuel lines (optional, but recommended)
- New fuel filter (recommended)
- Safety glasses
- Gloves
- Fire extinguisher
- Shop towels or rags
Procedure:
- Safety First: Disconnect the negative battery cable to prevent accidental sparks. Ensure the vehicle is parked on a level surface and the parking brake is engaged.
- Empty the Fuel Tank: This is the most crucial and dangerous step. Use a siphon or pump to remove as much gasoline as possible from the old tank into approved containers. Never attempt to drain the tank by disconnecting fuel lines and letting the fuel spill out. This is extremely hazardous.
- Support the Vehicle: Use a floor jack to raise the vehicle and secure it with jack stands. Ensure the vehicle is stable before proceeding.
- Disconnect Fuel Lines: Locate the fuel lines connected to the gas tank. Use a fuel line disconnect tool, if required, to carefully disconnect the lines. Have a drain pan ready to catch any residual fuel. Label each line to ensure proper reconnection later.
- Disconnect Electrical Connectors: Disconnect any electrical connectors attached to the tank, such as the fuel pump wiring.
- Remove Straps or Supports: Locate and remove the straps or supports holding the gas tank in place. These may be bolted or clamped to the vehicle's frame. Support the tank with a jack or assistance as you remove the last strap to prevent it from falling.
- Lower and Remove the Old Tank: Carefully lower the old tank to the ground. Inspect the area for any damage or corrosion.
- Transfer Components (If Necessary): If your new tank doesn't include a fuel pump or other components, carefully transfer them from the old tank to the new one. Be extremely careful when handling the fuel pump, and replace any worn seals or gaskets.
- Install the New Tank: Lift the new tank into position and secure it with the straps or supports. Ensure the tank is properly aligned and tightened.
- Reconnect Fuel Lines and Electrical Connectors: Reconnect the fuel lines and electrical connectors, ensuring they are securely fastened. Double-check your labels to avoid incorrect connections.
- Lower the Vehicle: Carefully lower the vehicle to the ground.
- Add Fuel and Check for Leaks: Add a few gallons of gasoline to the new tank. Inspect all connections for leaks. If you find any leaks, immediately tighten the connections or replace the faulty parts.
- Reconnect the Battery: Reconnect the negative battery cable.
- Start the Engine: Start the engine and let it run for a few minutes. Monitor the fuel system for leaks and ensure the engine is running smoothly.
- Dispose of Old Tank and Fuel Properly: Take the old gas tank to a recycling center or auto parts store for proper disposal. Dispose of any gasoline properly according to local regulations. Never pour gasoline down the drain or into the ground.
Real-World Owner Experiences
Many vehicle owners have successfully replaced their own gas tanks, saving money on labor costs. Here are a few common experiences:
- "The hardest part was getting the old gas tank down. It was heavy and awkward. Having a friend help made it much easier." - John S.
- "I replaced my rusty gas tank with a plastic one. It was a bit more expensive, but I'm hoping it will last longer in the salt and snow." - Mary B.
- "Make sure you have the right tools. I didn't have a fuel line disconnect tool, and it made the job much more difficult. I ended up having to buy one mid-project." - David L.
- "Don't underestimate the importance of safety. Gasoline is dangerous. I made sure to have a fire extinguisher nearby and worked in a well-ventilated area." - Sarah K.
FAQs About Changing Gas Tanks
Q: How long does it take to change a gas tank?
A: The time required can vary depending on your experience and the complexity of the vehicle. On average, it takes between 2 to 4 hours.
Q: How much does it cost to have a gas tank replaced by a professional?
A: Labor costs can range from $200 to $500 or more, depending on the shop and the vehicle. The cost of the gas tank itself can range from $100 to $500 or more, depending on the make, model, and material.
Q: Can I drive my car with a leaking gas tank?
A: No! Driving with a leaking gas tank is extremely dangerous and illegal. It poses a significant fire hazard and can cause serious environmental damage.
Q: How do I know if my gas tank is leaking?
A: Signs of a leaking gas tank include a strong gasoline odor, visible fuel leaks under the vehicle, and a sudden decrease in fuel efficiency.
Q: Should I replace the fuel pump when replacing the gas tank?
A: It's often a good idea to replace the fuel pump at the same time, especially if it's old or has a lot of mileage. This can save you time and money in the long run, as the fuel pump is located inside the gas tank on many vehicles.
Q: What should I do with the old gasoline I drained from the tank?
A: Take the old gasoline to a hazardous waste disposal facility or a local auto parts store that accepts used gasoline. Never dispose of it improperly.
By following these guidelines and prioritizing safety, you can confidently tackle the task of changing your gas tank and ensure your vehicle remains safe and reliable.
