Petrol tank filler neck and cap

From GTM Workshop

Build Manual Build Sequence Monocoque Front End Rear End Doors Finishing Donor Components Rover Metro Donor Components Rover 220/420 Components Build Sections Battery Beam end covers Bonnet and front spliter mould Boot bootlock and hinges Brake lines Carpets Dashboard cover Doors Engine cover moulding Engine frame Engine and auxiliaries Exhaust Front suspension Gear change Handbrake lever cables and calipers Door panels Trim Headlight covers Heater and pipework Lights Part trim panels option Pedal box and master cylinder Perspex screens rear and side Petrol tank filler neck and cap Pipes and services through the tunnel Radiator ducting and splash moulds to monocoque Radiator mould radiator and pipework Rear suspension Roof panel Seat belts Seats and runners Separate instrument option Setting up the car for the road Soft trimming Spare wheel mould and spare wheel Steering rack and column Throttle pedal Trimming hard panels Windscreen and rear bulkhead screen Windscreen washer bottle pipes and jets Wiper motor and blades Wiring Wiring loom insruments and fuse box 1800 gear change p.g.1 gearbox 1800 engine mountings 5AS alarm units Hydraulic clutch 1800 engine steady Spyder Supplement Top Seatbelt Mounting Hood Boot Engine Compartment Grills Stainless Steel Mesh

The Libra utilises the standard K Series Rover Metro petrol tank. The tank must be the appropriate one for the engine being used i.e. should the engine be fuel injected the tank must contain the appropriate fuel injection pump. The petrol tank mounts under the monocoque behind the seats. The standard petrol tank sender-unit is employed. A special flush fitting aluminium filler cap is mounted on the drivers side of the car and feeds through a special steel pipe through the monocoque into the petrol tank.

Assembly

Remove the fuel injection pump and the petrol gauges sender unit if separate from the standard K Series Rover Metro petrol tank. Ensure that all the petrol has been removed from the tank. It is essential that all the petrol be removed prior to working on the tank to prevent the chance of explosion. Where the filler neck enters the body of the petrol tank cut it so that it protrudes from the petrol tank 20 millimetres. Remove any bracketed that may be supporting the petrol tank neck on the standard K Series Rover Metro tank.

Where the large breather tube leaves the petrol tank cut the tube approximately 60 millimetres from the right angle bend. The various years of K Series Rover Metro petrol tanks had several different forms of venting the petrol tank. Apart from the large diameter breather pipe mentioned in the above paragraph cut of and seal up all the other breathers coming out of the tank.

The GTM breather is taken from a T Piece positioned in the ?? diameter breather pipe close to the petrol pipe adapter T0621 and as show in the drawing. The 6mm breather pipe is taken up into the driver’s side box section and back down through the same hole as the main petrol pipe and tie wrapped appropriately when it exits the body. This breather pipe wants to be kept well away from the exhaust system.

The petrol tank should only be fitted to the monocoque once all the services have been run through the tunnel including the handbrake cables. Referring to the petrol tank drawing in the manual position the tank under the monocoque and determine the appropriate position for the new holes that have to be drilled in the petrol tank flange adjacent to the tunnel of the monocoque. These holes want to be positioned so that the bolts would run through into the lugs provided in the monocoque moulding.

Remove the tank and drill the holes 6 millimetre clearance. Reposition the tank under the car and mark the two holes previously drilled and the other two mounting holes. Remove the tank and drill all four holes 6 millimetre clearance. Position the tank under the car again and mark the position for the filler tube to come through the monocoque and the large diameter vent pipe. Remove the petrol tank and hole saw two appropriate holes into the monocoque giving yourself a good clearance.

Replace the petrol pump and sender unit into the petrol tank. Attach 500 millimetres of the 5/16 ID petrol pipe to the original K Series Rover Banjo and attach to tank. Attach 1200 millimetres of 5/16 ID rubber pipe to the return on the petrol tank.

The petrol tank can now be attached to the monocoque using three 6 millimetre 25 millimetres long set bolts, washers and nylons and one 55 millimetre long 6 millimetre diameter bolt through spacer tube T0622 at the rear of the petrol tank.

Cut using a hole saw or by chain drilling the aperture for the petrol filler TO62O. Drill 5 millimetre clearance holes for the mounting bolts. Mount the petrol filler to the outside of the monocoque complete with its funnel. Using T0624 and the 50- millimetre ID rubber pipe 2 inches long attach T0621 adapter pipe between the filler T0620 and the petrol tank.

The so-millimetre ID rubber pipe 2 inches long can be slid onto the aluminium funnel and then with adapter pipe T0620 in place the pipe slid back over the gap. Insert the plastic T piece for the 6mm breather pipe into the ?? I D rubber pipe coming from the tank and reconnect the other side of the T piece to the adapter pipe TO621.

It is extremely important when you have completed you car and it is ready for the road that you check all the petrol pipe joins for leakage. Do not run your car until you are satisfied that there are absolutely no leakage's in the system.