Possible damage to Toyota Soarer fuel tank

Special care needs to be taken when re-installing fuel sender to the fuel tank. When the top steel plate is omitted during assembly and sender is fastened to the tank by 7 off M3 bolts and bolts are tightened, holes will be punctured in the top of fuel tank under the mounting flange because of the extra length of these bolts.

As can be seen in this photograph the circular flange with 7 threaded holes is spot welded to the top of fuel tank and sealing is achieved inside the flange through a rolled up edge of the tank skin. The 7 threaded holes do not extend through the skin of the tank.

When fuel sender is fitted without the steel plate, as shown here, the bolts (when tightened) will puncture the tank and cause severe petrol leakage.

When tightening the bolts, deformation to the tank skin under the flange will occur...

... and the skin of the tank will be punctured.

Repair is possible by welding or soldering around the perimeter of the flange but it is difficult to find a repairer willing to weld or solder a petrol tank.

Luckily, second-hand Soarer petrol tank was found at Sydney wreckers for $195 (just a bare tank without fuel pump or sender).