While changing fuel pump, opened up the tank and found something that's reminiscent of the Titanic wreck. Thick layer of rust on all surfaces, including hoses and interior of the tank. Fuel pump was basically oval from all the rusticles, and the filter under it was full of rust. Needless to say it was dead.

Is there a good way to get rid of rust in the fuel tank? Thanks for any info.

 

Honestly, I wouldn't try to fix it. Just get another. There are enough XJ40s for parts on ebay. I hope you get that car straightened out soon!

 

Mad_Russian,

I'm in agreement with Jerry. While it may be possible to treat and/or remove the rust from the tank, it will be difficult or impossible to know for certain that there are no areas so thin that pinpoint leaks may develop later, after you've done all the work to install the new fuel pump and reinstall the tank.

But before you install a good salvaged tank, you really need to figure out why your tank is full of rust. When I replaced the fuel pump on our '93, the inside of the tank was pristine - it looked brand new. For your tank to be covered with rust, my assumption is that you've had water in the tank for a long time. Have you had water in the trunk that might be leaking onto the top of the fuel tank, for example around the rear window or backlight seal? Has the rubber gaiter around the fuel filler neck filled up with rain water due to a clogged drain tube?

Please keep us informed.

Don

 

And....

Rusty tanks are common in cars that have been sitting unused for a long time. Or even a fairly short time of the conditions are 'right'.

Cheers
DD

 

+1

 

Update to the rusty tank situation.

According to the previous owner the car has been sitting for at least a year. There don't appear to be any leaks into the fuel tank, so I am not entirely sure where the rust came from.

I managed to get the rusty gasoline sludge out, and was pleasantly surprised to discover metal to be in good condition. The baffles on both sides of the tank, however were showing signs of rust (I had to bend them to be able to get into the areas on the side of the tank.

After some elbow grease time with metal brush, I water blasted the inside of the tank. That removed about 85-90 % of all the rust build up.

Next step was to buy 8 gallons of regular white vinegar and pour it into the tank. It's quite amazing what vinegar does to rust. I am currently in the process of treating the tank, but the rust is coming off and it's just clean metal that's left. Every few hours I rotate the tank to cover the new side.

So, so far everything appears to be on track. Thanks to all for information, but I believe the tank is quite salvageable. Once I am done, I will post pictures of finished work.

 

Excellent. I admire your elbow grease.