Yes, you must fit new rubber gaskets & use 'thread lock' on the screw threads as petrol could seep past the threads
Remember to stock up with the correct pipe clips - I found that motor factors don't seem to stock those very small ones that you may need for some of the breather pipes, but Vauxhall dealers keep them & they're cheap.
As a point of interest - on a Carlton that I broke up last year that had a new tank fitted, the person that fitted it had used cable ties instead of metal pipe clamps. This may seem like a 'bodge', but infact had worked without causing any problems during the last couple of years of the cars life.
Infact, after seeing this cable tie idea, I used them in conjunction with the metal clamps on some of the smallest pipes as double protection when I fitted a new tank to the estate earlier this year.
The mastic/rubber spacer strips that stop metal to metal contact between the tank & the body/chassis of the car, don't come with the new tank. I think some people don't bother to fit these when fitting a new tank. I think that they should be fitted & cut new ones out of some thin black rubber type sheet & stuck them on the tank before fitting
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Edit: Found some pictures of when I changed this tank.........
This is how a new tank comes from BuyPartsBy:-
If you have a tow bar fitted, you may have to release (but not remove) all of the fixing bolts, as the tank on the estates are hard up against the diff rear mount & the tow bar with NO clearance. You will probably need to completely un-bolt the off side tow bar mounting, as one of the bolts holds the tank strap on this side. With the bolts released, but not removed completely on the near side mount, the tow bar can be moved away from the lip of the tank. Take note that the near side mount goes behind the exhaust heat shield, so this stops the tow bar from being removed completely - without removing the back box & heat shield first.
In this picture you can see that the lip of the fuel tank goes behind a ledge on the tow bar:-
The new fuel tank has now had a coat of paint applied over the original factory coat as extra protection & you can see in this picture that I have cut out & stuck on the strips of rubber. In the background, you can see the old tank that has now been removed & how badly rusted it is:-
The question has been asked before - Is there much, if any, difference between estate & saloon fuel tanks & will one of one model fit the other? As can be seen in the picture below where I have put my spare saloon tank below the estate tank, the answer is fairly obvious - they are completely different tanks. I think it was Mr BC that told me on a thread somewhere in the distant past, that the Carlton estate tank IS the same as that fitted to a Monza........Below is the difference between estate & saloon fuel tanks:-
This last (& slightly out of focus for some reason) picture, is of the new tank being jacked into place with a trolley jack & a large piece of flat wood, ready to have the supporting straps re-fitted - you can see the tow bar hanging down out of the way on the off side:-
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Edit & Up-date - August 07...........
I have just fitted another fuel tank from a different supplier & the description of the findings etc. is to be found a few posts down on this thread which is to be found by clicking the link below
http://totalcarlton.com/forums/index.php?topic=7053.0
