Fuel return line inside tank

[woteva]

Anyone got a pic or diagram of how the fuel return line is supposed to look like ??
I have been having problems when getting to 1/4 tank and today have ripped out the sender/fuelpump to see that the return line inside the tank is broken off. I did check the Haynes and Max Ellery manuals but cannot see it in the pictures.
If there is any difference, its a VR V6 wagon. And I was able to get it out without dropping the tank

[delcowizzid]

pop that metal clamp off and slide the hose back on and use a worm drive hose clamp she be all good as new that fitting will come off the metal pipe to make the job easier.unless you have very small hands replacing the pipe will be a no go do you have children they have small hands LOL

[woteva]

I felt around in the tank with a finger or 2 and could not find the hose. So I got a mirror and torch for a look. I can see the swirl pot and the hose connection, but it is also busted off at the swirl pot

Managed to find some info from the Holden Service Manual - section 1.3 SWIRL POT

What to do now ???
I'm thinking about cutting the tank open, fixing the hose and welding it back up. I have cut and shut petrol tanks before for LPG conversions. So it should be no problem
With Xmas and all, I won't be able to tackle this until early next week. Bloody Xmas

[hako]

Great pix of the swirl pot and the lines woteva....never seen that one before so many thanks for posting. I'll bookmark this post for future reference and explaining to people who lose power when cornering with less than 1/4 of a tank.

[woteva]

I'll bookmark this post for future reference and explaining to people who lose power when cornering with less than 1/4 of a tank.

I will be removing the tank after xmas and will put up some more pix showing the repair.

[woteva]

Tank is now out. Washed out fuel and filled with water. Then left to stand for about 6 hours before cutting. Just picked up some hose and new clamps as well.

[RUF-IDL]

ive just done the same thing so dont know if you realise but u cant use std efi line inside the tank as the fuel will eat it. you need to buy submersable fuel line it costs around $50.00 a foot. cbc bearings @ regency park sell the hose

[woteva]

ive just done the same thing so dont know if you realise but u cant use std efi line inside the tank as the fuel will eat it. you need to buy submersable fuel line it costs around $50.00 a foot. cbc bearings @ regency park sell the hose

Was going to use standard fuel hose, thought it would be OK. It has fuel inside it, so it should be able to handle fuel on the outside of it ??
Otherwise I will have to wait until Tuesday and hope CBC are not on holidays.

[RUF-IDL]

deffinatly dont use the std line as it melts over time as its not designed to be submerged so you will end up with problems and have to fix it again.

[woteva]

Got a 30cm piece of submersible fuel hose from Repco for $27.00.
Now have to convince my friend with the mig welder that it is ok to weld a petrol tank

[Brett_jjj]

Someone told me you can run the exhaust fumes from a car through the tank while its being welded.The exhaust gas is inert,so no explosion.

[woteva]

Someone told me you can run the exhaust fumes from a car through the tank while its being welded.The exhaust gas is inert,so no explosion.

I have washed it out and let it stand full of water for 6 hours, so it should be ok to weld. Also it has been out of the car for a few days now.

About 15 years ago, I worked for a LPG conversion company and used to weld at least 1 used petrol tank per day. Some days I had 4 or 5 to do. Out of the hundreds of tanks that I cut in half and re-welded, there was only 1 that blew up
It was for another lpg conversion place and we made their tanks and brackets. They were in a hurry and wanted it back within 4 hours. I let it stand full or water for 2 hours which was not long enough. I had it on the bench, and when the 9" angle grinder just got through the surface, it wen't bang. The tank jumped up about 1 metre high from the bench. I jumped back about 3 metres and dropped the 9" angle grinder. The tank had blown up like a balloon

[woteva]

Got it all welded up and checked for leaks OK.
Will put the tank back in tommorow after work.
Will post some pics tommorow of my welding

[Abrowne70]

wanna do mine now? Finally rego'd my car again today after having done a pump and a few other things to find that on corners it just cuts out, pulled pump out, sure enough fuel return hose is off and split down the side.

[woteva]

wanna do mine now?

No. Doing my own was bad enough.

Gotta remember next time not to have as many beers before welding thin metal. I am blaming this on xmas and new year anyway.

Just put the tank in and only need to tighten the bolts and check hoses. It;'s too hot outside right now. Might wait until it cools down a bit.

WARNING: attempt the above repair at your own risk. Take every precaution when playing with petrol. Beware of ignition sources. etc.etc.
I have put up these pics as a guide to anyone wishing to tackle their own repair.

[markovr]

I know its a old thread but I have to post this
Cant believe this but my 12 yr old son has hands small enough to fit through the sender hole..he just undid the clamp and took the hose off...and replaced and did up .....took 2 mins...no welding no worries ...hes old enough and interested enough to understand how to do it ...cash reward is forth coming I reckon.

[markovr]

Just found out that holden service the return hosethat goes between the swirl pot and senderunit pipe and it comes complete with the connection to the sender unit pipe on it for 15 dollars part number92047898

[vr.ss]

I have bought the hose kit from holden but for the life of me cannot figure out how the connector works?! The is only a connector for one end- does the go on the swirl pot end or the fuel sender pipe end? Any pics or explanation on how it all goes together?