Fuel tank access hole

[Mogordo]

Can anyone tell me if this plate should ideally just come right off once the screws are removed? Not be very stuck? It is to access the hole that is located in the cargo compartment that allows you to see into the fuel tank.

[dlb]

Yes, once the screws are removed that plate can theoretically be removed. I've found it usually needs some love taps and/or prying to get it separated though. Once you have done it once it can be removed with the tank in place but that first time, I've always had to remove the tank to have good access to the plate.

[Mogordo]

Thanks dlb. I sure didn't want to remove the tank. Have to think on whether it's worth it at this point when I don't know if that will give me an answer to the problem or not. Thanks again, at least now I know. I tried some tapping and prying from the top but with the little room to work I didn't get anything noticable to happen. I didn't put much gas in it in case I did end up removing the tank so that's something.

[dlb]

removing the tank is actually not too difficult or time consuming. You just jack the car up, undo the screws and remove the trim around the gas filler neck, undo the two 14 mm (I think) bolts holding the tank up, and then lower it down on the straps. Once it's down you can remove the fuel hose from the top of the tank. That's it, IIRC.

[Mogordo]

Thanks dlb. That doesn't sound too difficult. Thanks for the breakdown.

[Mogordo]

Hi, Just finally got to actually looking at removing the fuel tank. Could you clarify if I figured this out correctly? I think the trim and screws for the filler neck are obvious enough but:

[Paul]

I would soak the front strap bolts and rear strap pins with penetrating oil in advance. I had difficulty with the bolts that hold the plastic tank protector to the straps. Once the front strap bolts are loosened, the tension on the strap pins is reduced enough to remove them. I pulled the tank towards the rear, leaving the front straps and tank protector in place. This method may not be the best for every situation, but I was challenged by rust too. Good luck!

[Mogordo]

Thanks Paul, I did spray with WD-40. Not the strongest stuff but better than nothing. The tank protector bolts actually looked in good shape if I remember correctly. There was more rust toward the back of the car than I realized...
I'm thinking then that I'm just going to end up starting to take it out and figuring out what to leave and what to remove as I go.

[Mogordo]

Well, One of the 14mm bolts snapped off when I had it turned about 3/4 in out. And the lines on top look about to be rusted through. How tricky is it to replace them?Possibly without snapping all those little bolts holding the plate on, that would be convenient. I was wondering how it is sealed around the lines. There is so much rust I can't tell.
Good news is that the inside of the tank looks fairly clean.

[Paul]

You might need something like PB Blaster instead of WD40. I'd apply it daily for a week before trying to remove those six bolts... maybe wire brush the tops first - so the oil can seep underneath. Hopefully, the rubber gasket below has protected the threaded areas.
Take a look at Rockauto under Fuel Line / Hose for the Tercel; the Spectra Premium FG81A fuel tank pickup line assembly is shown for FWD applications. This might work on the wagon after carefully "adjusting" the metal lines below the plate to fit. A local autoparts place could help you with a supply line strainer/filter. Take time to verify all lines when putting it back together.

[dlb]

Take a look at Rockauto under Fuel Line / Hose for the Tercel; the Spectra Premium FG81A fuel tank pickup line assembly is shown for FWD applications. This might work on the wagon after carefully "adjusting" the metal lines below the plate to fit.

I think someone here looked into this before and said it didn't work.

Ah, found the thread: viewtopic.php?p=113732&hilit=fuel+pickup+fwd#p113732

[Mogordo]

I knew the risk of one thing leading to another when I pulled the tank... But those lines really don't look good so good I did anyway.
That makes sense for removing the bolts. I'll use something stronger than Wd-40. Sounds like I might be in for a lot of thinking for the lines. Sigh.
Thank you both!

[SirFoxx]

I knew the risk of one thing leading to another when I pulled the tank... But those lines really don't look good so good I did anyway.
That makes sense for removing the bolts. I'll use something stronger than Wd-40. Sounds like I might be in for a lot of thinking for the lines. Sigh.
Thank you both!

wd40 is not a penetrant or rust remover. use pb blaster or similar fluid

[Mogordo]

Yeah, I've been spraying it with PB Blaster every day. I thought I didn't have any when I started with the fuel tank removal so I used WD-40 but then I remembered there was some in my other car. Might have not broken the 14mm bolt if I had used PB on it but those bolts didn't look rusty even and the other bolt came out easily once I intitially broke it loose. Oh, well.

[dlb]

Rust penetrants are a must of course but they are only part of the solution. You still have to have a really light touch on the wrench/ratchet/screwdriver, and the patience work things back and forth lots to break small, rusty, old nuts and bolts free without stripping the heads or shearing the shafts. Even then it's still pretty easy and common to mess up a bolt or screw, so you also have to develop an assortment of creative tricks for dealing with these things when you do accidentally destroy a faster.