Vanagon Gas Tank Removal Jack Reed First, a little about my experiences pulling VW gas tanks... I've dropped the tank in my van no less than 7 times trying to find and plug various leaks rather than shell out the $600!!! the dealer wants for a new one or take a chance on a used one. Hopefully you'll be able to benefit from my experience/bullheadedness 8-). One thing I would suggest is that if your tank leaks it's because dirt, oil, grease, etc. have found a home in the tunnel that runs the length of the tank. Water finds this the perfect place to reside while it slowly eats away the metal on the top of your tank. Once it's done it's business it's best to find a replacement since neither JB Weld or epoxy stemmed the leaks on my old one. YMMV, tho. Before you actually go and try this out, I'd suggest that you read this all the way through. My stream of consciousness style of writing lends itself more to abstract thought beforehand rather than instructions to follow once you're under the van. Just my $0.02 though since everyone does things a little differently. A couple of things about orientation here. All directions are from the drives seat facing forward. So obviously, right is the passenger side, front is the front of the van no matter which way _you're_ facing. Just a quick clarification for those who haven't done this kind of thing before. Introduction ------------ Before we actually get started talking about how to remove the tank, let's talk about what all goes to the tank and from where so we have some common reference points. There is a thick (2"?) metal tube that runs from the filler neck to the side of the tank. If you look inside the right side wheel well you can see where it goes into the tank. The tube fits into a rubber seal in the side of the tank. The tube itself fits into another rubber seal at the filler neck. The seal is held in place by 3 screws on the outside of the filler neck and by a worm clamp on the tank side. At the bottom/back side of the tank are two hoses. One (on the right side) feeds the fuel pump, while the other (on the left) is the fuel return from the engine. On the top of the tank, at the front are three holes with sealing rubber rings. Two of these (one on either side) fit into a plastic connector/hose arrangement that runs to the two expansion tanks on either side. The 3rd hole accepts the overflow pipe that connects to the side of the filler pipe, which is located on the right side. Also on the top of the tank are two other expansion tubes that are welded to the top of the tank and have inlets/outlets inside the tank. Somewhere in this maze of hoses is the charcoal cannister feed which then terminates at the air filter. For our purposes it's not important where it begins or ends. Getting Started --------------- While the tank can be removed with the van level, I always support the front on a pair of ramps. If you don't have ramps, don't worry about about it, they just make it easier to remove the beams. To start with, make sure that you've run the gas level down as low as you can. This will reduce the amount that will need to be drained from the tank later. Believe me, you want to remove this thing as empty as possible, since every gallon left inside is another ~8 lbs. for you to maneuver around whilst laying on your back. The job can be hard enough without having to deal with the extra weight. Drain any left in the tank by removing the hose that leads to the fuel pump on the right side. Make sure that there is a catch basin, gas can with a big funnel, etc. ready and waiting when you are. Remove the filler cap before removing the hose so that suction doesn't slow the drainage process down. On my 1981 Westfalia the tank is held to the body with two thick steel straps that run longitudinally. These are held to the body with two 13 mm bolts. Before you remove these though the filler pipe has to come out. Remove the filler cap and you'll see 3 phillips screw heads. Loosen these enough to be able to move things around without seperating the screws from the metal backing plate. There's a rubber seal in front of the backing plate that has a worm or screw clamp around it. Loosen this as well. You can get to it through the wheel well. Undo the clamp that holds the hose that goes to the overflow pipe and remove the hose. Use a big pipe wrench to twist the plastic housing that holds the filler neck. It's made to fit into cutouts in the body and when twisted about 3 degrees will come right out. Then grab the filler pipe and twist it back and forth until it comes out of the seal in the side of the tank. The plastic housing should be gripped and twisted from _inside_ the wheel well so you don't tear up the paint. If you've left too much gas in the tank it's all going to come rushing out the hole you've just made in the side of the tank, so make sure there's something there to catch the overflow. I would strongly caution you against having that much gas in the tank though. There should only be the dregs you can't get out by draining the tank first. Place a support of some kind like a jack or jack stand underneath the back of the tank to support it through these next maneuvers. From the drivers side wheel well you should be able to look up and see one of the expansion tanks. This tank has two small hoses that snake their way towards the gas tank. The hoses are held on by compression clamps and are a bear to get off. I've replaced the 4 clamps with worm clamps in case I have to do this again. I'd suggest you do the same. The clamps can be removed by holding the hose with one set of pliers while "wiggling" the clamp off with another pair. Be careful when you do this so you don't accidentally break off the plastic fitting from the expansion tank. Do the same thing on the other side. Ok, you should have the 4 expansion tank hoses off. Now comes the tricky part. Not really, you just need eyes on the ends of your fingers since you'll have to feel your way around the top of the tank. Look through the wheel well on the right side over the cross member that runs the length of the van. See the gap there between the member and the body? That's where we're going next. Reach through there and feel around on the top of the tank. From the right side you'll feel the overflow pipe where it fits into the tank and the hose and fitting arrangement mentioned earlier. They fit into two rubber seals in the top/front of the tank. Pull them out, then go around and pull the one fitting out of the left side. If you can't get to them, can't find them, don't know what the hell I'm talking about, don't worry. When you drop the tank, if you're careful they'll pull out by themselves. It's better to pull them out by hand first and take less risk damaging the seals and fittings. I've done it both ways and the seals are still good. Now we're ready to drop the tank. Get back under the van and make sure both hoses at the back of the tank have been removed. If you haven't removed the return hose from the engine yet, do so now. Make sure you have the catch basin/whatever there to catch what's left in the hose, since there's sure to be a little gas still trapped in there. If you can, fab up a cap for the two gas tank outlets, since there's going to be a little gas still trapped in the tank that'll trickle out when you drop the tank. A short piece of gas line hose with a big screw in it to plug it off works just fine. Undo the two 13 mm bolts, and twist the beams out of the way. Be careful when re-installing those beams that you get _both_ tangs back in place before you put the bolts back in. You'll see what I mean when you get them off. With your feet forward and you on your back, support the tank with one hand while you move your support out of the way with the other. Gently lower the tank towards you, feeling for hoses you may have missed, not gotten to. Once the hoses pull free, if you didn't get them earlier, support the front of the tank with your knees while you pull the tank towards you. There's a short shelf at the front lip of the tank that you have to pull the tank off before the tank will almost be free. You should have a bouncing baby gas tank in your lap at this point. Reach across the top/left side of the tank and pull the connector to the sending unit free. Slowly slide the tank off one hip until one corner rests on the floor. Slide/sidle the tank sideways until you can get out from under it. Pull it out the front of the van and go have a beer! You've earned it! The first time through is the hardest. Take your time getting everything apart and you should be ok. Putting it all BACK together ---------------------------- A couple of words of caution when it comes time to put everything back together. Get the tank up on the front lip and supported at the back, then get the respective hoses in their approximate locations. Then you can loosely bolt the tank in place while you secure the hoses at the expansion tanks and in the top of the gas tank. When you put the filler pipe back in, push it in a little farther than normal. Put the filler neck assembly back into the body being careful that everything is seated before twisting back in place. Be sure to have the filler pipe and the rubber seal approximately lined up before twisting the assembly in place and tightening the screws to give you a little freeplay to work with. Also, make sure the worm clamp is in place before you insert the pipe into the seal since there's no way it'll go in place otherwise. It's a little tough to get to, but if you work slowly you should be able to snug things up with no leaks. If you have any questions, comments or critiques feel free to reply to me at: jreed@ag.gov