Monday, Mar 12, 2007 at 18:08
G'day Trevor,
In my case the biggest time wasters were
1). trying to work out what the LVL valve is (this is where a diagram would have been a big help)........ as it turns out there is a breather type set-up just inside the sub tank. Access via
the big hole (of course) and you have to unclip the white breather gizmo that sits just above the filler pipe (inside the tank). A small mirror is handy so you can see what it is you're supposed to be unclipping. There are actually 2 of those breathers in the tank but you only need to use one of them in the new tank.
2). We
test fitted the tank and found that 3 of the slots (2 at each end) needed to be widened on the driver's side, to enable the bolts to fit in to the captive nuts to secure the tank......some careful work with the angle grinder was needed.
3). The lengthening of the float wire in the tank is a bit hit and miss. I bent up the new bit of wire so it matched the shape of the bottom section that actually holds the plastic float. I then cut the original bit of wire off near where it started to bend and tried to weld the new bit onto it. DAMN......too hot and melted the wire. Managed to get the joint done, but I reckon the float is gunna be about 30mm or more off the bottom of the tank at it's lowest point. This will mean the pump will cut-out (cos it thinks the tank is empty) when there may
well be 15+ litres of fuel still in it........time will tell. I have already thought out 2 options to correct it if this is the case. One will be to remove the back
seat again, pull up the carpet again, remove the sender unit again and try to do the job properly (a bit hit and miss for my liking). OR.....the more likely fix will be to hook up a momentary contact switch/push-button, so that I can manually operate the electric transfer pump to get the last of the fuel.
4). Re-fitting the 4 hoses. One is really easy; the pick-up hose which accessed through the hole in the floor. There is another one on top of the tank which fits onto a brass barb.....it's about 100mm on the driver's side of the hole, so you can't see it, only try to do it by contorting your hand into an un-natural pose. This may have been easier to do if it was done before the retaining bolts had been tightened up. The main filler pipe is a bit tight to get on, but my mate got it on for me..... The 4th pipe is actually the 16mm breather pipe, which involves another brass barb that is right next to the chassis at the rear of the tank. The rubber hose that is supposed to connect onto it was too short. I decided to use a piece of new hose 1.4m long and took it right from the brass barb back up to the top of the filler neck, thus bypassing the steel tubing that is there in the first place.
Hope this helps mate
Cheers
Roachie
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