How to replace a generator fuel tank in 6 easy steps

Got a generator with a leaky or busted fuel tank? Yeah, it might sound like a big job, but with some guidance, you can handle this DIY project like a pro. This step-by-step guide will show you how to swap out your generator’s fuel tank so you can keep your equipment running smooth.

Heads up: This info might not match your exact appliance model. We try to give solid advice for all kinds of DIY repairs, but different models can throw in some quirks. For the best tips, check your manufacturer’s documentation or reach out to us if you’ve got questions.

Safety first!

Before you jump in, let’s make sure you’re keeping things safe. Here’s what to do:

1. Unplug the spark plug wire: Turn off the engine and disconnect the spark plug wire so it doesn’t start up while you’re working.
2. Let the engine cool: Give it time to cool down to avoid any burns from hot parts.
3. Stay away from flames: Keep cigarettes, sparks, and open flames far from fuel to prevent any nasty surprises.

Let’s get started!

1. Drain the fuel tank

First up, you’ll need to empty the tank:

• For Champion generators: Open the drain screw and turn on the fuel valve to let the gas flow into a safe container.
• Other generators: Check your manual for how to drain fuel specific to your model.

2. Disconnect hoses and lines

Next, remove any hoses hooked up to the tank:

• Use a wrench to loosen and take off the fuel line and ventilation hose.
• If you’re worried about mixing them up later, label the hoses now.

3. Remove the tank bolts

The tank’s held down by some bolts:

• For Champion generators: Use the right socket (10 mm for most models, 7 mm for 3100-watt inverters) to remove the bolts.
• Other generators: Figure out the bolt sizes for your model and carefully take them out.

4. Slide out the tank

With the bolts gone, you can pull out the tank:

• Gently slide it out of the chassis toward the recoil end.
• If it’s stuck, double-check for any hoses still connected or other things in the way.

5. Install the new tank

Time to put in the new tank:

• Place the new tank where the old one was, making sure everything lines up.
• Screw the bolts back in—tight, but don’t overdo it.
• Reconnect the fuel line and ventilation hose, making sure they’re snug to prevent leaks.

6. Test it out

After everything’s back together, let’s make sure it’s all good:

• Fill up the tank with fuel.
• Check around for any leaks at the connections and hoses.
• Reconnect the spark plug wire and fire up the generator for a test run.
• Listen for anything weird and keep an eye out for leaks while it’s running.

Specific models and extra steps

Champion 3100-watt inverters

If you’ve got a Champion 3100-watt inverter, there are a couple more things to do:

• Take off the top yellow cover to get to the fuel tank.
• Use a 7 mm socket to remove the bolts holding the tank.
• Put everything back the same way you found it, making sure all parts are in the right spot.

MEP-802A generators

For MEP-802A models, it’s a bit more involved:

• You might need to remove the radiator and its support to reach the tank.
• Keep track of each step and all the screws and bolts for putting it back together.

Extra tips and tricks

Clean a rusty tank

If your tank’s rusty but not too far gone, you might be able to clean it up:

• Use hot water and a degreaser to get rid of fuel gunk.
• Apply a rust remover like Evapo-Rust to tackle the corrosion.
• Make sure the tank’s totally dry before you put it back to avoid new rust.

Check the fuel cap vent

A clogged fuel cap vent can mess with your generator’s performance:

• Look at the vent on the fuel cap to see if it’s blocked.
• If it’s not working right, you might need a new fuel cap.

Find your generator model number

Knowing your generator’s model number helps you get the right parts:

• Look for the manufacturer’s label on your generator for the model and serial number.
• If you’re not sure where to find it, check out our guide on how to find your appliance’s model number.

Wrapping up

By following these steps and keeping your generator’s specifics in mind, you can swap out that fuel tank safely and effectively. Doing it right means your generator will be ready to roll whenever you need it.

Need more help, tips, or parts for your generator? Swing by our repair help section at AppliancePartsPros.com. We’re here to back you up with all your appliance repair needs.

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If you’ve got questions or need a hand, don’t hesitate to reach out. Our team of experts is ready to help you get your appliances back in top shape.