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Date:         Wed, 05 Jun 1996 23:18:16 -0400
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         John Anderson <vwbus@netbiz.net>
Subject:      Re: vanagon gas tank remove

DAve, this is no big problem, to remove just follow common sense, first drain the tank with a siphon as much as possible, then pull either line coming off either side of the back, one is to pump one is return, and drain the rest. Standard don't be an idiot this is gas practices, fire extinguisher near etc. OK now disconnect both lines off the back. Next look under both wheel wells, you will see plastic vent/expansion tanks with 2 lines to each tank, a german cloth covered hose connected to the tank connected to a hard plastic hose, disconnect at joint between the hard plastic and rubber (you should replace the rubber likely). Now open gas filler, remove the 3 screws you see. Look at back of filler pipe, note smaller 1/2" pipe attached, pull it off the filler at the joint. Now take filler pipe, you will see it dissapearing into a rubber grommet through the frame into the tank. Work it into the tank a bit further while bending down and away from the body so you can get it in the wheel well opening then pull it out of the tank through the wheel well. OK now support the tank with a nice jack or shim it up with something you can remove when lowering. Observe the 2 steel straps holding the tank, bolts at the front, tabs through the cross beam at the back, unbend the tabs going through the cross beam, and unbolt the straps, remove the straps The tank should then lower out easily enough, watching for the lines for the vents, etc. One 1/2" vent line goes side to side over the front end of the tank and is held to the body with a clamp, this one may come out of the grommets in the tank, deal with it later. Disconnect the wire to the sender and it twists out of the tank using something to turn it between mounting tabs. Chances are a tank from PA is severely rusted out on top, now is the time to asess yours and do whatever you see fit, some hand wire brushing and good rust prevent oil based paint at least. Replace as you removed, now a good time to replace all those fuel lines and fuel filter BTW. The whole process is not that bad really, out took me about 1 hour first time, back in in about 45 minutes.

John NOW vwbus@netbiz.net


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