Leaking fuel tank

[wonderman]

Goodday everyone... Has anyone replaced the passenger side fuel tank on a Stevens Esprit. I have a 1990 SE and the tank started to leak the night after I replaced the surgical vent tube. Coincidence?? Anyway the problem I'm having is getting it out . The side wall which houses the airbox is off as well as the trunk floor and relay wall. Everything is out of the way but I see no way to remove it without taking the entire side of the quarter panel off.
Need advise please.

[lotusman]

According to the manual,
"To remove a fuel tank, drain both tanks and disconnect and plug all fittings. Remove the trim panel, engine bat wall, seat belt reel and fuel filler neck. Release the locating bolt fitted to the lower inboard side of the tank, and the fuel tank retaining board and withdraw tank. Note, that it may be necessary to remove the engine mounting legs and lower the engine slightly to provide sufficient clearance."

Hope this helps. If you do not own a manual yet. GET ONE! There is a small hose which appears to be under the filler hose. If the clamps are not right, this would appear as a leak.

[wonderman]

Thanks Lotusman but I tackled the job myself without the manual. Everything you mentioned is right except lowering the engine. I found it much less trouble to remove the intake plenum cover than to lower the engine , this gave me just enough room to lift the very awkward tank up and out . However the crossover outlet at the bottom of the sump canister was hooking on everything on the way out. The complete wiring harness has to be disconnected as well as the vacuum lines.There was no way I was going to pay Lotus for a new tank so I had a Tin Smith fabricate me a new one based on the old design out of stainless. It worked perfectly and cost me nothing as I work at Ford. The tradesman here love to do side jobs. Now all I have to do is worry about the drivers side tank.
Sincerely
Scott

[nemick]

Wonderman,
Pray to God in Heaven that the driver's side tank does not have to come out. I had to replace mine and after doing it, I would most certainly remove the engine entirely if I had to do it again.

[lotusman]

Wonderman, where was the leak on the tank? Something I should look for in the future. Thanks for the method.

[wonderman]

The leak was on the bottom directly where it contacts the foam . I am assuming that the foam was there for cushion but it was a very bad mistake on Lotus's part. This is a major repair and one I hope that not every one is cursed with. The reason for the foam getting wet is suppose to be the rear quarter window leaking down the inside but my window does not leak so it must also get wet from driving in the rain . Who knows !!
Good luck