Petrol tank woes

After experiencing the same problem with my '89, 3.5 RR I made a call to the local rover shop. He suggested the "gas tank sealer kit for cars" [Item No. - 10165 Z ] from

. He also suggested that Ipurchase an extra bottle of "gas tank sealer" [Item No. - 10087 Z ]. This will come out to nearly $63.00 U.S. before shipping. I'm sure you will be able to find something similar in the U.K.

Heres some American RR News for you dated 30-11-95:

Fuel Tank

A defect which relates to motor vehicle safety exists in 1987 through 1990 and some 1991 model year Range Rover vehicles imported by Land Rover North America, Inc.

DESCRIPTION OF DEFECT Land Rover has identified a defect in the fuel tank fitted to a number of

1987 through 1991 Range Rover vehicles. The Defect could lead to corrosion at the bottom of the fuel tank in the area above the stone guard. If the corrosion were to perforate the fuel tank wall, fuel would seep into the space between the tank and stone guard producing fuel odors. If the odor were unnoticed or ignored, fuel leakage could eventually result and present a fire hazard in the presence of an ignition source. Reported failures are primarily from areas where road salt is used during the winter. However, all affected vehicles will have the fuel tank inspected/ replaced.

VEHICLES INVOLVED/CUSTOMER NOTIFICATION U.S. and Canadian 1987 through 1991 Range Rover vehicles within the VIN ranges shown below are involved in this recall action: Model Year Model VIN Range 1987 All HA265406-HA301324 1988 All JA300620-JA344935 1989 All KA336636-KA395665 1990 All LA391190-LA457333 1991 SXGD MA442792-MA462136

CUSTOMER NOTIFICATION LETTER November 30, 1995

Dear Range Rover Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Rover Group, Ltd., manufacturer of Land Rover vehicles, has determined that a defect which relates to motor vehicle safety exists in some 1987 through

1991 Range Rover vehicles within a specific build range. The defect may or may not be apparent in all vehicles, however, the part will be replaced on all affected vehicles within the specified build range.

The Defect could lead to corrosion at the bottom of the fuel tank in the area above the stone guard. If the corrosion were to perforate the fuel tank wall, fuel would seep into the space between the tank and stone guard producing fuel odors. If the odor were unnoticed or ignored, fuel leakage could eventually result and present a fire hazard in the presence of an ignition source.

Reported failures are primarily from areas where road salt is used during the winter. However, regardless of where you live or drive, the fuel tank will be replaced at no charge to you. This action is being taken voluntarily and the necessary work can be performed by any authorized Land Rover retail dealer.

The parts necessary to complete this action are currently available at your Dealer and the time required to perform this work is approximately 2 hours.

If you have already had the fuel tank in your Range Rover replaced, it is possible that the tank may not have to be replaced again. Your Dealer will be able to confirm the kind of fuel tank that is currently in your vehicle and whether or not it will have to be replaced. If you paid for all or part of having a fuel tank replaced, kindly provide your dealer with a copy of your receipt for having the work performed and you will be reimbursed.

Please contact your Land Rover Dealer to arrange for this work to be performed as soon as possible. Your dealer is prepared to make the modification as convenient as possible for you at a time that fits your busy schedule. If you experience any difficulty in making these arrangements, please contact one of our Owner Care Representatives at 1-800-637-6837.

If your Dealer does not repair your vehicle without charge and within 60 days, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, Washington, D.C., 20590, or call the toll-free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call ((202) 366-0123). You may also call our Owner Care Department or write to:

Land Rover North America, Inc.

4390 Parliament Place Lanham, MD 20706 Attn: Owner Care Department

Please note, if the vehicle to which this notice applies has been leased and you are the lessor, you should send a codv of this notice to the lessee. We apologize for any inconvenience caused by this recall, but trust that you understand the need to have this condition rectified. Land Rover North America Barbara R. Wheatley Manager, Owner Care

Thanks for all that, Jack -

Here's looking forward to getting back 'on the road'.

a new diesel tank for my 90 was about 100 pounds from Paddocks, incl. all seals etc. Was a peice of cake to fit.

I had precisely the same problem with an 82 3.5 and it's most likely not a small leak. By "seal" I assume you mean the flange that runs right along the rear of the tank. If so then be aware, this is spot welded to the tank and crud accumulates between the tank and the flange and causes the tank to rot.

If you poke around with a screwdriver I can almost guarantee you will find that the entire seam will hole quite easily.

Get a new tank. £75 quid shipped from Paddocks for a Britparts pattern tank.

I would also order a new sender unit while you're at it as you stand a better than evens chance of wrecking the old one getting the tank out.

If your fuel pipes are in anywhere near the state mine were in (age hardened) then you are likely to find it quite difficult to refit them to the new tank, so get some 5mm and 7mm fuel pipe from Halfords or nearest equivalent and a set of jubilee clips.

It's not a difficult job to do and can be done with the car on the ground, just make sure to drain all the fuel from the tank before starting to release it, as a tank full of petrol will ruin your day (and ribs) if it falls on you.

Go through the nearside wheel arch to remove the wires from the sender unit along with the fuel feed pipe. You will need double jointed fingers for this, but it's perfectly doable. Go under the drivers side and remove the large filler hose from the tank and the filler neck, along with the thin breather hose. If either of these have perished then phone Paddocks for another one before going any further.

Assuming yours is a RR and not a Defender then there are 3 nuts along the trailing edge of the tank with captive studs in the body work. The nuts are nylock types and will take a fair amount of force to move, even if they aren't rusted. If they are rusted then attack with a penetrating oil and leave for a few hours. Do *not* get tempted to go at them with a blowtorch to loosen them.

There are also two bolts at the front edge of the fuel tank along with the fuel return pipe. Remove the fuel return pipe from the tank and then get a spanner in on the top of the bolts on the inside of the bracket they run through on the bodywork and then just undo them as normal. These bolts run through brass collars which in turn run through a set of rubber washers providing a shock mount for the front of the tank. Make sure not to lose the washers otherwise things will get *very* noisy when refitting them. If you lose any bits then the whole bolt/washer/collar assembly is available from LR dealers for around £5.00.

Fit the sender unit (either the old one from the old tank, or the new shiny one you ordered from Paddocks) to the new tank on the ground. Paint the new tank if you want (I didn't as I don't expect the car to last more than another 18 months).

Fitting is the reverse of removal as they say.

Figure on it taking around 3 hours including swearing time and getting sensation back in your fingers.

P.

Thanks for that full talk-through. Yes, it's a RR, not a Defender. Busy weekend of swearing coming up, it seems!