Date: Sat, 15 Jun 2002 15:25:33 +0100
Reply-To: Anthony Polson <acpolson@HOTMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Anthony Polson <acpolson@HOTMAIL.COM>
Subject: Re: Leaky gas tank fix?
Content-Type: text/plain; format=flowed
Hi John,
I have exactly the same problem. There is no other way of solving it other
than replacement, and I have just ordered a new gas tank.
The Vanagon tank is an abomination. Whoever designed it should have been
fired long before being allowed to inflict such a bad design on Vanagon
owners worldwide. I suspect that the same designer may previously have
contributed to the design of the Super Beetle (1302, 1303), but I digress.
Because of the several large hoses that run the full length of the Vanagon,
the fuel tank had to be set low in the vehicle to allow the hoses to pass
over it. The need to maintain good ground clearance also meant that a
normal rectangular-ish tank would have been too small, so the top of the
tank was raised outside the central area (where the pipes run) to allow a
greater capacity.
This results in a large, low, flattish central area between the two high
peaks of the tank. This central area is a perfect breeding ground for rust,
because moisture easily gets in there but finds it difficult to get out.
Even regular steam cleaning would not sure the problem IMO, so it's just bad
design. It is possible that your front tank seam is leaking, but I think
it's more likely that the central area has rusted through.
Vanagons from 1985 on had a different fuel filler neck which does not fit
the 1980-84 Vanagon tank. VW no longer offer the 1980-84 tank so you will
have to buy the later tank plus a new filler neck. My supplier (in the UK)
offers a kit with all the parts - you may find that one or more of the parts
suppliers on this list will do the same.
The new tank is very easy to fit, but an "empty" old tank is a massive
hazard. That's because it contains a lethal mixture of air and fuel vapor.
You must take great care to avoid sparks or naked flames. No-one must smoke
anywhere nearby. You should stay safe until either the tank has been taken
away from you, or you have disposed of it, and the new one has been fitted.
Now to the job. First drain the old tank, either by going for a long drive
(!), or removing the flexible pipe from the rear passenger side corner of
the tank. Then remove the filler neck, starting with the flange behind the
fuel filler cap.
Now all you need to do is remove the tank. It is supported underneath by
two longitudinal pressed steel sections. Each of those sections is bolted
to the main chassis rails at the front with a single bolt. Support the tank
with a scissors jack, or a hydraulic bottle jack and a timber pad. When
that bolt is removed, the steel section can be pulled towards the front
bumper, disengaging it at the rear. The section and the tank will be
released and will fall uncontrolled to the ground unless it has been
supported.
Fitting the new tank is the reverse operation. I intend to paint the whole
tank with a flexible high adhesion paint that will resist future corrosion,
and will apply several coats to the very vulnerable semi-dished section
before fitting it.
Maye sure that you obtain a full set of new seals and the resilient pads
that go between the longitudinal steel sections and the base of the tank
itself. The fuel gauge sender seal is especially important, and it may be
worth fitting a new sender at the same time. If you need to see drawings of
these parts, try the Russian on-line version of the EKTA parts catalog at:
http://catalog.exist.ru/
Good luck. HTH.
Best regards,
Tony
======================
--Original Message--
>Date: Fri, 14 Jun 2002 22:59:18 -0500
>From: Jon Joyce <okartguy@HOTMAIL.COM>
>Subject: Leaky gas tank fix?
>
>I noticed a fairly strong gasoline smell emanating from my '81 tonight,
>several hours after filling the tank. I crawled underneath, and sure
>enough,
>there was a wet area on the bottom of the gas tank. It's still fairly small
>and not dripping at all, but I assume it will only get worse. It looks to
>be
>leaking from the seam on the side parallel with the nose of the van. What
>course of action should I take? I seem to recall seeing this discussed
>previously on the list; is it a common malady? It also looks like it should
>be fairly easy to drop the tank... of course, I just put 15 gallons of gas
>in it. Any help would be much appreciated-
>
>JJ
>'81 Transporter
>"In the end she will surely know I wasn't born to follow."
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