I put in the new tank with a new sender as well, and had to tweak the tabs on the tank opening before I could install the sender. It was too tight as Joe discovered, and I also used silicone spray to lube the O-ring. Neil, the crossover pipe goes over the coolant pipes, that's why it's a PITA to do without dropping the tank down at an angle, but not too steep an angle. It's intended to pass air, not fuel, between the two camel's humps as the fuel sloshes around, and you don't want fuel trapped in it. Stuart -----Original Message----- From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Joe T. Sent: Tuesday, March 12, 2013 9:49 AM To: vanagon@GERRY.VANAGON.COM Subject: Re: Gas leaking after filling to the top...84 2wd.. I just did this (again) a couple of weeks ago. I did the reseal using the Van Cafe kit three years back, but didn't replace the fuel gauge sender or, more importantly, the O-ring that seals it to the tank. Recently a massive leak developed there, and even if I filled up 3/4 full you could still smell gas around the driver's side. On full fill-ups, gas would visibly leak down from the sender area. I also have been fighting the buzzing fuel pump issue since I bought this particular Vanagon almost eight years ago. This time around, I decided to bite the bullet and go with the newer-style tank with the larger outlet to the fuel pump, discard the plastic pre-filter in favor of the big metal cylindrical after-pump filter, and replace the sending unit and its o-ring completely. I have to say that this is what I should have done last time. The only issue I had was getting the new sender into the new tank. It was a bear to get in, and I ended up shattering it into three pieces by trying to muscle it too much with a big wrench. Thankfully, there was nothing wrong with my old sender, and with a new o-ring, it went in fine. Although it sucks to watch fifty bucks shatter into three pieces... I'm happy to report no constant gas smell, full fill-ups, and a nearly inaudible fuel pump.
> > -- > Joe T. > '85 Wolfsburg Westy Subie 2.2 |
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