Hey guys this weekend I was installing my walbro 255 fuel pump and when I was putting it back in, one of the 5/16 nuts that bolts the plate to the fuel tank sheared the bolt in half. And OF COURSE, the bolt right next to that one is stripped so the nut does not tighten down all the way. So my fuel pump gasket is leaking...

My guess is that the best/cheapest way to CORRECTLY fix this problem would be to drain the tank, fill it with water to relieve the fumes, then drop the tank. Once the tank is off of the car I was going to drill both of these studs out of the tank and replace them with grade 8 bolts. Hell I might just go ahead and do it to all six bolts. Does this sound like the correct way to fix this problem? Or does anyone have any other advice?

No one has any advice for me before I plunge into this thing this weekend?

-Justin


-96 RS
-98 GSX

Avoid any and all sparks. Use a screwdriver and put the new screw in that way if you have to, you want to avoid sparks as much as you can.. you could let that gas tank sit outside for as long as you want, and fill up and drain it as much as you want, but it could still explode for no reason.

1995 Eagle Talon ESi

Drop the tank first then fill with water.

I fully understand what you want to do and it could work. There is a cleaner you can get for the tank, buy it use it. Any gas that sits on top the water can catch fire. Filling with water will reduce the chances of open sparks as long as the gas residue does not get a chance to ignite while contained.

By filling with water you need to make sure there are NO air pockets in the tank.


how do you plan to hold the new bolts in the tank?

Terry

That is the $1,000,000 question. I haven't dropped the tank yet, my car is still sitting out in my driveway. I think I am just going to have to end up buying a new tank, because I can not think of a way to hold that bolt into place WHILE being able to completely tighten down the o-ring for the fuel pump. The only thing I can even think of is to weld the bolt into place from inside the fuel tank, but that is not going to happen seeing as I don't want to accidentally set fire to any existing fumes in the tank. Anyone have any other suggestions so I can save $170 by not having to buy a new tank?? haha

I wouldn't half ass this in any way. Your best option may just be getting a new or used tank.

Joel Baldridge, ASE Certified Master Technician, Audi Certified Expert Technician

I'll be attempting to salvage the tank with the help of my girlfriend's dad at his shop. He has owned his own shop for over 15 years. Basically... if we can't get it done together, I'll know beyond a shadow of a doubt that the tank can't be saved. But we are going to give it a shot, after all we have nothing to lose lol.

For what its worth a junkyard tank cant be very much.

Is it a stud or a bolt?

If it's just a bolt and you stripped the threads of the recieving end, drill out the hole clean and tap it to one size (possibly two) larger, buy corresponding bolts.

As for the fumes thing... water sounds good, I'd just put a hose in there and leave the water running, shake the tank a bit, or roll it around to try to let air pockets escape, and if the cost of water doesn't bother you, leave the hose on when doing the work.

__________________________________
-Ryan

I haven't really gotten a chance to see if it is a bolt or a stud. If it is indeed a stud, I am going to see if there is a possibility that I can just replace it with a bolt instead but who knows. It is looking like I am going to be needing to get a new tank at this point. I really just want to get the damned thing fixed so I can get on with the SFMU install and proceed with the rest of the custom turbo kit install.