Installing the Reconditioned Fuel Tank With the engine refurbished and reinstalled, along with the radiator and engine accessories, the next phase in the restoration of the 1969 Alfa is the installation of the fuel system -- including the refurbished fuel tank, fuel pump, fuel filter, fuel lines, carburetor and exhaust system. In this segment, the restored fuel tank is checked and put back in the vehicle. Following is a summary of the fuel-tank installation as shown in the episode.
- When the fuel tank was removed from the vehicle, it was checked for damage and corrosion, and sent to be professionally reconditioned to bring it back to operating condition. Checking the condition of the tank on the outside only tells part of the story. An old automobile that has been in storage for a long time will likely have corrosion inside the fuel tank. A good indicator of this is the rust on the bottom surface of the gas cap (figure A). Removal of the sending unit from the tank allows a visual check of the inside of the tank, which also indicated internal rust.
- To refurbish the tank, it was checked for leaks, boiled, cleaned and then lined with a new urethane liner. For our project car, this process was done by professionals. There are kits available from car-restoration product suppliers that allow the advanced do-it-yourselfer to tackle this job.
- The sending unit (figure B) was checked to make sure that it was still functional and cleaned. It was found to be in good enough condition to be re-used.
- Because the restoration of this Alfa involved converting from a fuel-injection system to a carburetor system, the fuel-injection return line on the fuel tank was sealed off with a small rubber cap and hose-clamp (figure C). The hose clamp was installed just snug -- not too tight.
- With the fuel tank thoroughly checked, and the return line capped, the tank is ready to be installed into the vehicle. The fuel tank is lifted into the trunk where it drops into an opening in the trunk (figure D).
- Once installed, the top of the fuel tank sits flush and actually functions as part of the floor of the trunk (figure E). A rubber seal around the lip at top edge of the tank serves as a weather seal and helps keep moisture out of the trunk.
- With the tank in place, it is lined up using an awl and then secured with sheet-metal screws around the perimeter of the tank (figure F). The screws are tightened snug, with care to avoid over-tightening them.
- The fuel evaporative-emission hose is secured using a hose-clamp (figure G ) to an outlet that's adjacent to the fuel-filler inlet neck (figure H). The original hose was in good enough shape that it did not need replacing, but the small hose-clamp used to secure it was replaced.
- Finally, the fuel-tank installation was completed by re-attaching the fuel-supply line underneath the vehicle (figure I).
Tip: In the fuel-tank replacement, as well as throughout most of the mechanical restoration, all of the old hose clamps were replaced with new ones. Hose clamps are inexpensive, so it's generally a good idea to go ahead and replace them when the opportunity arises during the course restoration. The small expense of replacing the old clamps far outweighs the risk of a major system failure that could result from a broken clamp -- a situation that might lead to a costly repair. In the segment that follows, the fuel pump, fuel filter and fuel lines are installed.
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Order this book from Amazon.com
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