Time for a refuel.

As with all jobs, the tank refurb took a bit of time - the joys of trying to fit van-maintenance around everything else in life! Still, slow and steady for this type of job is not a bad idea - allows tank time to full dry out before the refit.

As mentioned in previous posts, I replaced the rubber grommets on the tank. The old ones weren't in bad condition, but as I don't plan on dropping the tank again any time soon it made sense to replace with new - these came from Just Kampers and there are three of them on the tank top - two for the expansion tank breathers and 1 for the filler pipe breather.

Once the grommets are in place, push the expansion tank hose plastic pipes into the holes.

I replaced all of the expansion tank breather hoses with new 5mm fuel hose. The following photo shows the ones that I hooked up before putting the tank in place again (refer to previous posts for fuel system diagram):

I didn't put the filler neck breather back in at this stage.

Here is the tank ready to go back on the van:

Now comes putting the tank back on the van. With the front of the van up on axle stands, I moved the tank back underneath. I then lifted the end of the tank up and moved a trolley jack underneath, locating the shoe roughly in the centre of the tank. I was then able to slowly jack the tank up into place a little at a time, making sure to:

1. Remember to plug fuel lever sensor back in.
2. Don't trap any wires or hoses.

One the tank was a little way up, I fed the filler neck and breather through from the top of the wheel arch and slotted them into their grommets in the tank. Pull through the expansion tank hose ends to.

Then, you're ready to lift the tank fully into place and refit the tank straps - mine had a fresh coat of black Hammerite straight to rust before fitting.

Once the tank is up and secure, slid the filler hose into the rubber neck and tighten up a jubilee clip around it.

Slide the 5mm expansion tank hoses onto the tanks and that is job done!