Date: Tue, 7 Aug 2007 22:44:37 -0600
Reply-To: alfred bagdan <abagdan@SHAW.CA>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: alfred bagdan <abagdan@SHAW.CA>
Subject: Re: fuel tank replacement
Content-type: text/plain; format=flowed; charset=iso-8859-1; reply-type=original
I had the same type of fuel leak when filling up completely. Drove for a
few years by not totally filling the tank.
In most cases, the three rubber grommets on top(one on the drivers side and
two on the passenger side) need replacing, as they are old and shrunk a bit,
thus allowing fuel to seep out when overfilling. One can replace them with
not too much difficulty without dropping the tank. This is the cheap way to
go. However it probably is false economy. It is better to replace all the
grommets, hoses and some of the plastic tees. You can buy a kit with
everything needed (more hose clamps would be nice) from Busdepot or Vanagain
for about $80. Dropping the tank is not too difficult, there are various
write-ups in the archives. By dropping the tank you can also check the
condition of the top. Mine had some rust spots in some of the low places.
The rust will develop when the gas is spilled and now sits in the low spots,
causing the paint to dissolve and expose the steel. Then as you drive
though puddles, water will get to these spots and start the rust. Over the
years, the rust will eat a hole in the tank and you will need to replace
the tank (if you haven't caught fire yet and burnt the van up yet), in
which case you will need to buy a new tank (or van). I wire brushed the
rust spots to bare metal with a brass brush attached to a drill and was
lucky that the rust had not yet progressed too far. Then I repainted the
top of the tank with 3 coats of automotive rust paint, and put everything
together using all the parts of the tank kit I bought. The filler tube
grommet comes with the kit and was also replaced, even though it was not
leaking yet. The job is not too difficult, provided you have an inventive
nature to solve the problems as they crop up. Drove to the gas station and
filled up as much as possible and no leaks.
Good luck
Alfred
85 Westy
----- Original Message -----
From: "pepperd" <heymrpep@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, August 07, 2007 11:12 AM
Subject: fuel tank replacement
> hey all
> just finished about 900 miles of travel from ri to downeast maine,
> checking out a lot of the little communities from ellsworth to jonesport.
> saw about four vans the whole 6 days, including the two ladies from maine
> who took the last site at lamoine state park (we were second to last 20
> minutes earlier) right next to us. saw a bay westy on 295 in portland
> heading back yesterday. the whole time the van ran great, yet, alas a
> problem. instead of the sometimes regurgitation of gas out of the filler
> when the pump popped to indicate a full tank, two small leaks in the fuel
> tank within a few minutes of filling. one is at the seam, passenger rear,
> where there was quite a bit of rust. grabbed some epoxy stick and it
> seemed to do ok.
>
> foiled, the evil and calculating tank decided to leak on the next fill up
> on the driver side, near the top center but i can not really see from
> where it is coming(the wife didn't need to hear about the second one, she
> barely got in the van after the first). we drove the rest of the way home
> putting no more than 9 gallons in at a time(once we got near 1/8th or so
> on less than accurate gauge), and no leaks. one repairable leak i can
> live with, but since i need to drop the tank to find the driver side one,
> i'm gonna replace it. the questions:
>
> in replacing the tank, what parts should/must i replace besides the tank
> itself? grommets? filler tube? overflow? all of above? others? i want
> to make sure i have all the parts on hand when i start the job.
>
> i have a 1981 ac parts van---will the tank from it, if in good shape, fit
> my 1984 boxer(11/83 manufacture)?
>
> has any one posted a good how to/ how not to do a tank job?
>
> what parts should i think about replacing that dropping the tank will give
> me access to? i did my coolant pipes earlier this year, figures i have to
> drop the tank now(damn murphy's law). my emergency brake rod is pretty
> rusted up and that was the first thing that sprang to mind. Others?
>
> thanks for thoughts
>
> don p
> 84 westy
> carolina ri
>
>
>
>
>
>
> ---------------------------------
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