Date:         Sat, 6 Dec 1997 12:42:54 -0400
Reply-To:     mark keller <kelphoto@BRIGHT.NET>
Sender:       Vanagon mailing list <Vanagon@Gerry.SDSC.EDU>
From:         mark keller <kelphoto@BRIGHT.NET>
Subject:      Gas Tank vent leak repair with tank installed 91 Carat.
Content-Type: text/plain; charset="us-ascii"

My van had the dreaded gas tank leak.  One list member said that this could
be done without pulling the gas tank. They're right!  Jack er up, support
the thing, remove both front tires, and be patient. It took me about 1 hour
start to finish.

  The famed and flamed vent line breaks right at the tank, so you can
actually reach in and feel the plastic fitting and the broken joint. Once
you remove the A/C line support bracket and move the A/C hoses out of the
way,  My vent line broke at the drivers side "y" fitting, which I'll bet is
the common break point, since it's the closeset to a retaining clamp on the
vehicle.

 After I began the repair I noticed that the "clamp" which I guess is used
to keep the vent line up high, which is not needed since the vent line is
made from ridged plastic pipe, anyway the clamp postion is fixed and really
puts too much strain on the pipe,  I feel it's this clamp's position and
stressing the plastic pipe and plastic fittings that causes the damage.
Next time my left front tire is off, I'm going to rig up some type of
elastic shock absorbing clamp, to keep it from happening again.

I bought the vent line, since its ridged plastic the whole thing comes
assebeled with the fittings installed, the two grommets, and you need 3' of
5.5 mm hose.To attach the second port of the fitting to the plastic tanks
on either side of the van. The hoses are different lengths, but the book
says 1 meter of hose is all that's needed for both sides.

Using the new vent line as a guide I located the smaller hoses and
disconneted them.  Then I removed the broken side fitting with small hose
attached to measure the lenght needed for the new vent line.  Put that
amount of hose on the correct side, use the remaining hose on the other
side.

 I got the whole affair ready to go,and then I started from the passenger
side of the van so I taped the driver's side new small line to passengers
side old small line and then slowly pulled and fished the old line out and
the new line in place at the same time.

To install the gromments I lubed the exterior part of them and the hole in
the tank, then i jammed one on my finger and felt for the hole.  This is
the toughest part of the job.  I dropped one and spent a few minutes
fishing it out, don't panic, it's tight, and I'm 6'3" and 220lbs, and I
still got my hands and arms in there. I used a standard drop light to "see"
the hole and then felt my way toward it.  I use a wet cloth to clean around
the hole to avoid brushing excess dirt in the hole whilst I navigated by
clumsy touch and contortion of the tight space.

Well that the gas tank vent line repairs. A dirty little job at best, If
your capable of working in tight spaces, it much easier than dropping that
whole fuel tank, at the worst it's best to try this first, if you can't get
it, or talk a buddy into helping you get it done, then I guess dropping the
tank is you only other option.

Sincerely Mark
91 Carat WE
"Lazarus"