Date:         Sun, 13 Mar 2005 22:08:05 -0500
Reply-To:     Edward Maglott <emaglott@BUNCOMBE.MAIN.NC.US>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Edward Maglott <emaglott@BUNCOMBE.MAIN.NC.US>
Subject:      fuel tank removal story
Content-Type: text/plain; charset="us-ascii"; format=flowed

I did the fuel tank removal and replacement today in order to correct the
gas drips and smell when filling the tank.  Having taken the tank out, I
think what was leaking was the old fuel line material.  The small diameter
stuff that goes to the expansion tanks.  I hear about re-doing these fuel
lines without removing the tank.  I can see how you could replace the ones
that attach to the bigger crossover piece, and the 3 grommets, but I don't
think you could replace the 2 pieces that connect to the metal overflow
tubes attached to the tank.

I had driven my fuel down very low.  I thought I was clever in gaining
control over the fuel pump to help me with the tank draining process.  I
read the procedure for testing the output of the fuel pump.  It has you
remove the right hand relay in the box above the coil. (this is a 2.1 liter
engine, 86 vanagon).  Then it has you jumper the 2 center contacts (top and
bottom) in the relay socket to run the FP.  I remember this winter one of
our listees got a gasoline shower by not considering the residual pressure
in the system when he cracked a hose.  So first thing I did was pull that
relay.  Turned ignition on, no fuel pump humming.  Started the engine, it
ran for a surprising amount of time on residual pressure.  Maybe 15-20
seconds.  OK, next I removed the hose after the fuel pump, which I was
going to replace anyway.  Only a few drops of fuel came out.  Hooked a
length of fuel hose to it and put the other end in a clean gas can.  went
back and jumped the contacts in the relay socket as specified.  Fuel pump
went to work and emptied the tank for me.  Probably only a gallon or so, so
it didn't take long.  Note that when you jumper this thing, the fuel pump
runs regardless of the key being turned in the ignition switch.

I followed the tank removal instructions in the Bentley, and some good
instructions Ken W posted some time ago.  It was pretty
straightforward.  While I had the tank out, I sloshed the remaining gas
around in it and then dumped out.  I am curious what the internal anatomy
of the tank is, especially related to the outlet and return
fittings.  Where do they go?  I lean the tank in their direction but
nothing comes out of them.  I go to dump the gas out of the fill hole, and
it spills out of the outlet and runs down my leg!  I don't think I ever got
any to come out of the return opening.  I also cleaned the outside of the
tank which had a lot of dirt on it.  I have found this same dirt in large
quantities all under the van.  It apparently went on quite an off road
adventure with a PO.

Putting the tank back in was harder than taking it out as usual.  that
crossover pipe has to be in place under the van and then hooked up after
the tank is almost in place.  I put the grommets in the tank first as Ken
recommended and this is a good idea.  I also used a little grease on them
so the fittings would slide in.  There is really no room to get the
leverage to push them in.  I had the great idea that as I put on all my
hose clamps, I would cut off the excess "tail."  This left sharp edges that
menaced me as I reached around under there, so don't do that.  I also put
the crossover pipe fitting in the wrong grommet on the passenger side and
had to pull it back out.  I should have checked which one it was, or at
least looked at the photo in the manual, duh.

So I put my gallon of rescued gas back in the tank and decided to use the
jumper relay trick to get the gas flowing back through the rest of the fuel
system.  I hook up my wire and hear a strange trickling sound.  Forgot the
hook the new hose from the filter back to the fuel like running to the
engine!  OK, it's getting late, I'm getting tired, my fingers are
sore.  Fix that last problem, get the van off the ramps, and go to the
nearest gas station.  I fill up the tank nice and full and revel in the
lack of dripping gasoline!  No gas smell either!  One more pesky job off
the list, and the van is one more step closer to the way I would like it to be.

Edward