300tdi D90 fuel tank change ...

Never done one before, my mate (who knows everything LR) said, "it's a bit of a fiddle" ....

Well, he's not wrong.
I left the car for a week and when I came back the slight damp-patch i'd noticed was this ...



The new tank's cover wasn't the straightest and there was a lot of tension at one end ... out came the grinder ...



Couple of taps with a hammer, bit more off, then the welder ...

Quick rub down with some 120 grit, followed by a wipe with some brake cleaner/IPA and a rattle can of Mr Buzzwelds 2K paint

To get the old one out is a real fiddle, everything seems to hit everything else.

I took the panel off under the drivers seat to access the top pf the tank and unscrewed the return outlet and senser.
I'd never seen a sensor before .... It's held in with a ring that you need to rotate 90 degrees.
I used a socket and cut some notches to grab the little tangs ....



There are two bolts holding the rear of the tank to the outrigger and 1 (special shoulder bolt) with rubber washers at the front.
The front bracket is bolted to the front outrigger with 3 M8 bolts.
They need spindly long fingers and 3 13mm spanners to get them off. Which you need to do to get the tank out.




Here's my new front bracket loosly fitted ... i've sprayed some Lanoguard around too.

You also need to remove the filler hose and the breather pipe from the filler nozzel/tank, otherwise the tank just doesn't come out.
I took me a while to figure that out DoH !

It was total b*stard getting the shiny new one in on mine without scratching it, took many attempts - there is a way but it took me ages to accidentally find it and it plopped in without issue….

…the neighbours learnt some new words along the way.

perseverance

When I did mine last year for better access took out the floorplate and and the sill rail.

Thanks for the photos, very useful. It's amazing how a galvanised part really does highlight its location.

It's a pity the shield on the tank isn't removable as I find the mud and moisture trap in-between really frustrating. It looks like you have done a great job preparing and painting it, yet you can't get to the rust inviting bit!

Not a lot can be done about protecting the space between tank and shield. I got a can of spray waterproof grease and blasted it in the gap with an extended tube.
Do not do as some have and try and seal the gap with some sort of sealant, sooner or later it will give and water will get in and stay in, then the rot soon sets in.

I sprayed copious amounts of fluid film in mine.

I spayed a load of lanoguard, in will spray more today.
The new tank and guard are deffo thinner than the original, however, I suppose I should of expected that as it's a sh*tpart variant.

slomofo said:

It was total b*stard getting the shiny new one in on mine without scratching it, took many attempts - there is a way but it took me ages to accidentally find it and it plopped in without issue….

Click to expand...

Tell me 'the way' ?

@tottot has the answer. Floor plate and sill rail, then loosen the forward mount bracket a smidge

Bit more today ...
Took your advice and dropped my rock-sliders and the sill U channel.
Of course that opened up a can of worms uncovering more rotten bits requiring attention.




Decided i'd make up some new stainless bolts for the rear of the tank ...
Small plate, hole and TiG an M8 on .... easy .... I thought

Usual crud.

It's in ..... now I need to reassemble the sill and add the fuel lines etc.
Anyone need some help with thier tank change ?
Free advice as long as i'm more than 100 miles away




That front bracket made me swear, a 'bit of a fiddle' doesn't cover it.

I was lucky in that my front bracket was still good, still getting there now.

All done, bar testing for leaks etc ...



Note to self: Hold your stomach in next time ....

Last wee job was to spay the whole car with rust remover ....

Wrong vehicle, that's a Lancia Beta.