Date:         Thu, 20 Sep 2012 12:12:39 -0600
Reply-To:     david hardy <david@PLANETMIND.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         david hardy <david@PLANETMIND.NET>
Subject:      Project Report : gas tank reseal
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Just fixed my 1990's leaky gas tank, and thought I'd share my experience for the benefit of
those who think they might undertake the project, since it seems it's a pretty common problem.
It was quite a pain, though it will definitely be easier next time around. Helps to know where
everything is on top of the tank - it's all really well hidden.

Getting all the gas out of the tank turned out to be almost impossible, so I ended up doing it
with about a gallon of gas in there, which made the tank pretty unwieldy. Getting the tank out
was pretty easy - the hardest part was getting those darn factory hose clamps off the braided
lines going to the expansion tanks. Next time, I'd just cut those hoses since you'd be dumb not
to replace them - and all the pieces of braided fuel lines under there for that matter.

Turns out my problem wasn't the seals at all, but that the crossover vent hose had come off the
T-connector on the driver's side. If it were the other side, it might have been possible to
reattach it by reaching in there through the wheel well (after taking the wheel off). Probably
worth checking to see if that's your problem before pulling the tank - and before spending $$ on
all the seals and tubing. All my seals looked fine - it was the braided vent lines that were in
bad shape.

Getting the thing back in involved a bit of pain, esp. working alone...it has to go in
front-first, which of course is where all the vent connections are. So you can only hook up one
side of the crossover hose, since it has to go *over* a bunch of stuff. Since you have access
thru the passenger wheel well after the tank is in, I left that side disconnected, and was able
to push the fittings for it and the filler vent pipe into the seals after getting the tank
installed.
All told it was about a 4 hr job. Sure is nice not to be breathing gas fumes every time I fill
up, though.

David
'90 Westy
'86 Westy
'83 Diesel Westy