Date:         Wed, 19 Oct 2016 12:19:58 -0700
Reply-To:     Stuart MacMillan <stuartmacm@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Stuart MacMillan <stuartmacm@GMAIL.COM>
Subject:      Re: Fuel leaking from Sender Unit on Replacement Fuel Tank
Comments: To: Richard Koerner <rjkinpb@sbcglobal.net>
In-Reply-To:  <1212190076.3739321.1476904132389@mail.yahoo.com>
Content-Type: text/plain; charset="utf-8"

Is it a big fat one, green in color? That’s what I used from Van Café.

 

Stuart

 

From: Richard Koerner [mailto:rjkinpb@sbcglobal.net] 
Sent: Wednesday, October 19, 2016 12:09 PM
To: Stuart MacMillan; vanagon@GERRY.VANAGON.COM
Subject: Re: Fuel leaking from Sender Unit on Replacement Fuel Tank

 

Yes, the VDO sender unit was supplied with a new o-ring.

 

  _____  

From: Stuart MacMillan <stuartmacm@GMAIL.COM>
To: vanagon@GERRY.VANAGON.COM 
Sent: Wednesday, October 19, 2016 12:04 PM
Subject: Re: Fuel leaking from Sender Unit on Replacement Fuel Tank


Did you use a new O-ring?  Bending the tabs is required for a tight fit as well, but you need the ring to be soft enough to deform a bit when tightened.  

Stuart


-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Richard Koerner
Sent: Wednesday, October 19, 2016 11:59 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Fuel leaking from Sender Unit on Replacement Fuel Tank

I recently replaced the Fuel Tank and the Sender Unit on my 85 Vanagon; I purchased these from Van Cafe and had my VW mechanic install.  Initially had a BIG leak when filling up the tank.  Mechanic dropped tank and spent time bending and adjusting the tabs that hold the Sender Unit to get a better fit with the o-ring, and used a straightedge to try for as flat a surface as possible.  The leaking stopped (he pressure-tested and smoke tested)...but has now re-appeared when filling the gas tank to full.
It appears that MANY aftermarket tanks and Senders have this problem.
I'm thinking of applying some epoxy putty (gasoline resistant) when installing the Sender to fill the potential gaps of the mating surfaces.  Maybe some of the epoxy between the mating surfaces, and then build up a fillet of epoxy around the perimeter of the Sender Unit?
Any advice on this issue?  Van is currently over at mechanics....we are scratching our heads for a permanent solution.

Rich
San Diego