Fuel tank install

1

Hi all,

Still working through my tank install. For those that have or are planning to, attached is the section of the federal code covering this modification.

I have located an approver (Bris) and will show him what I have and how it installs to confirm it complies before fitting. I have found it always better to run through a modification with an approver prior to doing the work, rather than reading the code and turning up with the job done and hoping it passes.

In short, the tank install need certification!

If the attachment does not work, you can find it under this link:

Vehicle Standards Bulletin 14 (VSB 14)



Look at section LM


Richard


2

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard

3
Hi Richard,

My mechanic installed mine and had no issues with the set mounts but note my seats are no longer installed so the bolts are not there (just the nuts).

The two straps seem fine but we just added some extra rubber to ensure it doesnt move.

The Fiama filler and clear hose work well - no issue so far with fuel in them.

The clear pipe makes it easy to see how well the fuel is going in.

The pump/ fitting and other instructions were fine and it works really well in place now.

Only problem is emptying the tank when the van is level or facing downhill.

Fuel pumps in well using the pump / fittings supplied but the pump is quite noisy. I might upgrade it to something quieter later on....

For now its great!

Cheers,

Skot

On 3/08/2015 2:51 AM, cathrich1@yahoo.com.au [Syncro_T3_Australia] wrote:

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard


4
Hey Folks,

By the way, I have a 38L stainless steel fuel tank which my Dad had custom made with baffles etc and never fitted. It was supposed to be a tandem fuel tank for his syncro but he ended up just fitting the single side tank.

It has no mounting hardware or filler hoses etc and it is designed to fit on the drivers side of the syncro.

My dad said it had a small leak when he tested it but both he and I never got around to fitting it before the South African ones came up.

Anyway it is shaped correctly to fit in the space provided and will just need someone to trace the leak, fix it then its ready to go in.

Let me know if anyone wants it and I will get some pictures of it.

Cheers,

Skot

On 3/08/2015 9:25 AM, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] wrote:

Hi Richard,

My mechanic installed mine and had no issues with the set mounts but note my seats are no longer installed so the bolts are not there (just the nuts).

The two straps seem fine but we just added some extra rubber to ensure it doesnt move.

The Fiama filler and clear hose work well - no issue so far with fuel in them.

The clear pipe makes it easy to see how well the fuel is going in.

The pump/ fitting and other instructions were fine and it works really well in place now.

Only problem is emptying the tank when the van is level or facing downhill.

Fuel pumps in well using the pump / fittings supplied but the pump is quite noisy. I might upgrade it to something quieter later on....

For now its great!

Cheers,

Skot

On 3/08/2015 2:51 AM, cathrich1@yahoo.com.au [Syncro_T3_Australia] wrote:

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard



5

Hi Scott, yes had seen all your details before,  thanks for resending :)

Did yours get an approval per the vehicle code?

The point about being able to over fill the main tank is a problem and that connection has the potential to do that if you forget how much is in your main tank or your fuel gauge is out.

On the tank fitting, yes it's the nuts that protrude (seat bolts are no longer than the nuts), so I assume your mechanic is either pulling the tank hard up against the nuts, or he has packed something above the tank for the brackets to pull hard up against. I feel better knowing mines hard against the floor, plus I gain and extra 10mm ground clearance!


With the filler, just get worried when it's labelled as water, I know Ian said they are all the same. I'm happy to have a factory one though, the check in the filler prevents any surging getting to the filler.


If some on takes you up on the spare tank, I'm happy to pass on the FIAM filler and fuel pump as I won't need them :)


Richard

6
Hey Scott, I am interested in the fuel tank. could you let me know your price and how far you are away from Melbourne?

Regards,


Michael

On Monday, August 3, 2015, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

Hey Folks,

By the way, I have a 38L stainless steel fuel tank which my Dad had custom made with baffles etc and never fitted. It was supposed to be a tandem fuel tank for his syncro but he ended up just fitting the single side tank.

It has no mounting hardware or filler hoses etc and it is designed to fit on the drivers side of the syncro.

My dad said it had a small leak when he tested it but both he and I never got around to fitting it before the South African ones came up.

Anyway it is shaped correctly to fit in the space provided and will just need someone to trace the leak, fix it then its ready to go in.

Let me know if anyone wants it and I will get some pictures of it.

Cheers,

Skot

On 3/08/2015 9:25 AM, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] wrote:

Hi Richard,

My mechanic installed mine and had no issues with the set mounts but note my seats are no longer installed so the bolts are not there (just the nuts).

The two straps seem fine but we just added some extra rubber to ensure it doesnt move.

The Fiama filler and clear hose work well - no issue so far with fuel in them.

The clear pipe makes it easy to see how well the fuel is going in.

The pump/ fitting and other instructions were fine and it works really well in place now.

Only problem is emptying the tank when the van is level or facing downhill.

Fuel pumps in well using the pump / fittings supplied but the pump is quite noisy. I might upgrade it to something quieter later on....

For now its great!

Cheers,

Skot

On 3/08/2015 2:51 AM, cathrich1@yahoo.com.au [Syncro_T3_Australia] wrote:

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard



7
Hi Michael,

As the stainless in it cost a lot and it has been shaped up and welded with baffles I would like at least $50.00.

Problem is I am on NSW Central Coast and its longer than a metre so it cant be posted.

Cheers,

Skot

On 6/08/2015 11:45 PM, Michael Carpenter mikey.p.carpenter@gmail.com [Syncro_T3_Australia] wrote:

Hey Scott, I am interested in the fuel tank. could you let me know your price and how far you are away from Melbourne?


Regards,


Michael

On Monday, August 3, 2015, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

Hey Folks,

By the way, I have a 38L stainless steel fuel tank which my Dad had custom made with baffles etc and never fitted. It was supposed to be a tandem fuel tank for his syncro but he ended up just fitting the single side tank.

It has no mounting hardware or filler hoses etc and it is designed to fit on the drivers side of the syncro.

My dad said it had a small leak when he tested it but both he and I never got around to fitting it before the South African ones came up.

Anyway it is shaped correctly to fit in the space provided and will just need someone to trace the leak, fix it then its ready to go in.

Let me know if anyone wants it and I will get some pictures of it.

Cheers,

Skot

On 3/08/2015 9:25 AM, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] wrote:

Hi Richard,

My mechanic installed mine and had no issues with the set mounts but note my seats are no longer installed so the bolts are not there (just the nuts).

The two straps seem fine but we just added some extra rubber to ensure it doesnt move.

The Fiama filler and clear hose work well - no issue so far with fuel in them.

The clear pipe makes it easy to see how well the fuel is going in.

The pump/ fitting and other instructions were fine and it works really well in place now.

Only problem is emptying the tank when the van is level or facing downhill.

Fuel pumps in well using the pump / fittings supplied but the pump is quite noisy. I might upgrade it to something quieter later on....

For now its great!

Cheers,

Skot

On 3/08/2015 2:51 AM, cathrich1@yahoo.com.au [Syncro_T3_Australia] wrote:

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard




8
Hi Michael,

Attached are a few photos of the tank.

Its quite long as it fill the void completely.

It has fixing brackets at either end and the inlet runs under the chassis rail behind the drivers wheel arch.

It needs the vent pipe replaced as I think that's where it leaked?

Otherwise its in great condition.

Cheers,

Skot

On 6/08/2015 11:45 PM, Michael Carpenter mikey.p.carpenter@gmail.com [Syncro_T3_Australia] wrote:

Hey Scott, I am interested in the fuel tank. could you let me know your price and how far you are away from Melbourne?


Regards,


Michael

On Monday, August 3, 2015, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] <Syncro_T3_Australia@yahoogroups.com> wrote:

Hey Folks,

By the way, I have a 38L stainless steel fuel tank which my Dad had custom made with baffles etc and never fitted. It was supposed to be a tandem fuel tank for his syncro but he ended up just fitting the single side tank.

It has no mounting hardware or filler hoses etc and it is designed to fit on the drivers side of the syncro.

My dad said it had a small leak when he tested it but both he and I never got around to fitting it before the South African ones came up.

Anyway it is shaped correctly to fit in the space provided and will just need someone to trace the leak, fix it then its ready to go in.

Let me know if anyone wants it and I will get some pictures of it.

Cheers,

Skot

On 3/08/2015 9:25 AM, Scott Pitcher spbconsulting@bigpond.com [Syncro_T3_Australia] wrote:

Hi Richard,

My mechanic installed mine and had no issues with the set mounts but note my seats are no longer installed so the bolts are not there (just the nuts).

The two straps seem fine but we just added some extra rubber to ensure it doesnt move.

The Fiama filler and clear hose work well - no issue so far with fuel in them.

The clear pipe makes it easy to see how well the fuel is going in.

The pump/ fitting and other instructions were fine and it works really well in place now.

Only problem is emptying the tank when the van is level or facing downhill.

Fuel pumps in well using the pump / fittings supplied but the pump is quite noisy. I might upgrade it to something quieter later on....

For now its great!

Cheers,

Skot

On 3/08/2015 2:51 AM, cathrich1@yahoo.com.au [Syncro_T3_Australia] wrote:

Getting a little closer on the tank. Seems nothing is quite straight forward!! I've also done things a little differently to how Ian intended.

Firstly, I could not put the tank in fouling with the seat mount bolts, tank is now notched to miss the bolts!

Not sure what everyone else has done, but the brackets seem setup to pull up against the bolts, I have had to shorten all the brackets to allow for the 10-15mm height difference now. I am using 4 mount brackets instead of two. The extra two at each end of the tank needed modifying to fit as the body shape varies along the outer sill.

I have used nutserts for the brackets instead of the coach screws supplied.

The tank was supplied with clear fuel line and a FIAM water filler cap. Have others used this for fuel??

I have gone for a factory filler, looks factory and mounts neatly, it also lets me use the factory ball/check in the filler neck and the factory vent line for filling.

Next, to get to approved the engineer was concerned on the fill method, it does not prevent overfilling of the main tank. This can lead to choking the charcoal canister or worse still pumping fuel out where ever it leaks first (air cleaner??), Made sense and can understand their concern.

Anyway, I have yet to finish off the install, but current plan is to run an EFI pump and pump directly into the EFI ring main (EFI pump has a one way check on the outlet). This way I can select which pump to run off, when on the secondary tank, return fuel from the ring main will still go to the main tank. The over flow of the main tank can now drain back to the secondary tank, so prevents being able to over fill the main tank!

It also means the factory filler cap is sealed, and the secondary tank can breath correctly through the charcoal canister.


The EFI pump with the kit is different to the original (larger body and larger outlet port), so I am getting a factory pump!


Mud flaps also progressing, not perfect but hope they are functional.


Richard




9
Bit late on this topic, I have installed tank no problems a cutting template would have helped. I agree the pump is noisy and will probably try a spare vw that have. Didn't like the tec screws holding the brackets so used nut inserts  
Colin
10

Hi all,

I have drained my main tank, thankfully fuel came out spotless.


Does anyone know how much fuel is left in the tank after you drain it? Just wondering how much crap could be stuck in the bottom that won't drain out?

Richard

11
I just went through this process. Depends on how you drained the tank. I used the fuel pump until it stopped pumping. Then I pulled off the side entry flange and used a siphon tube at the base of the internal filter (you can reach in easily). About 300mls came out and mine was full of rubber particles from the internal fuel return line.
Then I added about a liter of fuel (through the normal filler cap) at a time to rinse the tank.

12

Thanks. I just removed the outlet hose (to the pump) to drain.

As I was testing the new aux tank setup with dual pumps, I ran the motor for a while on each pump and the return fuel from the ring main was draining straight out the tank. In total I would have flushed ~15L through the tank, nothing came out.

I did not look inside the tank like you did, but sounds like a good idea. I do need to remove my tank to check the breather system though, so will get to it some time soon.


I traced the leak in the breather system to a perished grommet on the roll over valve, I have patched this for now with a fuel resistant sealant (Permatex from Super cheap).

Just shows that old German rubber is past it's used by date!


Richard