How To Repair A 2003 Infiniti G35 Fuel Tank Filler Neck

How to Repair an Aluminum Fuel Tank in a Boat

by Chris Stevenson

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Aluminum marine gas tanks do not terminal forever since they endure corrosion and exposure to the environs like whatever other gunkhole component. However, aluminum has its advantages over other materials used for gas storage on marine vessels, chiefly that it combats corrosion ameliorate and weighs less than other heavier metals, including some fiberglass tanks. Fuel leakage from an aluminum tank requires an immediate response, since liquid gas and fumes institute a danger to onboard passengers. Finding and repairing a leak in an aluminum tank need non be difficult and but requires some practical steps and basic tools.

Footstep 1

Trailer the boat to a convenient piece of work location and park the tow vehicle with the emergency brake ready. Remove the lanyard key from the ignition. Disconnect the negative battery cablevision with a socket. Close off the main fuel feed valve at the tank and at the engine. Employ a screwdriver to loosen the gas intake hose clench and pull the hose from the gas tank neck.

Step 2

Disconnect the fuel belch line that goes to the fuel pump with a screwdriver. If equipped with a vent hose, unclasp the hose end or loosen the clamp with a screwdriver. Disconnect the tank sensor wire, if so equipped.

Footstep iii

Place a siphon hose in the gas intake inlet and pump out the gas into a certified container. Remove as much gas as possible. Use a socket and wrench to remove the strap or subclass bolts that hold your gas tank to the stringers or bottom deck. Be careful not to tear whatsoever rubber mounts or insulation under the tank.

Footstep 4

Use an assistant to help yous remove the tank from the boat and set it on end over a suitable drainage area. Drain any remaining fuel from the tank into a certified container.

Step 5

Use a high pressure water hose to flush the inside of the gas tank, removing all gas traces. Use a compressor air nozzle to force-blast all moisture from the tank. Set the tank on cease, assuasive it to drain and air dry completely. Place the tank in a position to piece of work on the damaged area.

Stride vi

Chalk an outline of the crevice or corroded area, allowing at least a iii-inch overlap. For a small scissure or hole, use a drill and conical flake to grind a bevel in the cleft, or open upwards the pigsty to produce new metallic on the sides of the hole.

Step seven

Apply 400-grit sandpaper to sand over the fissure surface area or hole, overlapping the area on all sides by three inches. For a corrosion spot, sand over the entire corroded area down to blank metal and overlap on all side for three inches. Don gloves, a particle mask and goggles. Wipe the area down several times with acetone and a rag. Wipe dry with a rag.

Step 8

Mix the contents of the marine epoxy weld according to directions. Mix the epoxy agent with the hardener solution in a cup and stir vigorously. Apply the epoxy weld chemical compound over the scissure or damaged surface area with a putty pocketknife, using force per unit area to shove it downwardly into the fissure or hole.

Step 9

Use potent pressure level to force the epoxy compound inside the tank. Build upwards a several layers of epoxy weld over the damaged expanse, extending out to your chalk marks. Permit the epoxy weld dry out and cure co-ordinate to directions.

Footstep 10

Have your assistant help you place the tank back in the boat. Align the straps or brackets and insert the mounting bolts. Tighten the bolts with a socket. Reconnect the principal fuel intake hose and tighten the hose clench with a screwdriver.

Pace xi

Hook up the discharge fuel line and tighten the clamp with a screwdriver. Supplant the fuel vent hose and snap the clasp or tighten the clamp with a screwdriver. Reconnect the fuel tank sensor wire, if y'all have removed one.

Refill your gas tank with the reclaimed gas from your containers. Check for leaks.

References

Tips

• You tin repair the gas tank with HTS brazing rod, using a torch to heat up the aluminum surface until the rod flows and fills in the cracks. The surface preparation and treatment is identical to the cold epoxy weld procedure. You will use flux to prep the metal before welding and a slag hammer to knock off $.25 of residue.

Things You lot'll Need

• Siphon (paw pump)
• Gas cans
• Socket set
• Ratchet wrench
• Assistant
• Water source (loftier pressure)
• Air compressor
• Chalk
• Drill motor
• Cone bit
• Sandpaper (400 dust)
• Gloves
• Condom goggles
• Particle mask
• Acetone
• Marine weld epoxy
• Plastic cup
• Putty knife
• Screwdriver

Warnings

• No smoking or ignition sources should be immune nearly the boat or gas tank while performing this process. Even slight fumes can ignite, causing injury.

Writer Bio

Chris Stevenson has been writing since 1988. His automotive vocation has spanned more than 35 years and he authored the auto repair manual "Auto Repair Shams and Scams" in 1990. Stevenson holds a P.D.S Toyota certificate, ASE brake certification, Make clean Air Act certification and a California smog license.

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