Smelling fuel from your Vanagon when you're at the pump? Perhaps you were parked on a slope and returned to see a spreading puddle of gasoline under your van? Uh-oh...Time to do that fuel tank reseal you've been putting off! Our Vanagons have a relatively complex fuel storage system, with vent hoses, expansion tanks, filler neck hoses, O-rings, seals, and crossover pipes--oh my!! This CAN be a DIY job but it's messy and smelly. You're also dealing directly with gasoline, so be sure to take appropriate precautions: Wear eye protection, skin protection, old clothing, and have a fire extinguisher VERY handy. Also, disconnect your battery and no smoking for the duration of the procedure. Lastly, it can take an experienced Vanagon shop four hours to do the job; Home mechanics should bank on more. 

You'll need our fuel reseal kit and a filler neck seal. You'll need a 13mm socket and ratchet, various pliers, a crimper, and a jack can be handy as well due to the weight of the tank. You also require something to SAFELY capture the fuel you'll be draining from your tank (gas can, etc.). We also make sure to filter the storage container (gas can) so no contaminants can fall in while you're under the van-- it's dirty under there! NOTE: Make absolutely sure that the container you have for catching and storing the drained fuel has ample capacity for the fuel remaining in your tank. You'll be well rewarded by running your tank as low on fuel as you feel comfortable with. Less fuel in the tank=less fuel to drain and store while performing the reseal. The following is a condensed version of the tank removal procedure; please refer to your Bentley Manual for illustrations of the tank and system and the official fuel tank removal procedure. 

Here's a quick step by step of removing your tank: 

• Disconnect the negative (ground) cable of your battery. We don't want any stray sparks here... 
• Drain the remaining fuel from the tank by removing the inlet and outlet hoses. There will be fuel in the tank to catch, but remember that there will also fuel in the lines. Also, keep in mind that if the van has been driven recently the fuel may be pressurized. Hold a rag around the hose as you disconnect it to catch the spray. REMEMBER: FIRE HAZARD!!! 
• If you're working with your van on the ground, it's not a bad idea to put a floor jack under the tank as a safety precaution. Don't put any upward pressure on the tank - we're not lifting it here, but rather supporting as we remove the tank securing mechanism. 
• The tank is secured by two straps that are slotted into the frame of the van at the rear and by two, 13mm-headed bolts at the front. Remove these bolts being careful to note that the straps may spring-about a bit. Also, if the tank shifts from level, there may be some residual fuel that needs to be caught. 
• Remove the rear of the straps from the slots in the van frame and the tank will start to come down in the rear. Again, catch the fuel that you'll inevitably find spilling out. 
• When you gain access (you may have to lower the tank by lowering your jack) to the fuel vapor hoses that head up to the expansion tanks (in the wheel wells), remove the hoses from the tank. 
• Loosen the clamp from the filler neck at the tank. 
• On most vans, you'll see three screws that hold the filler neck to the main tank body. Remove these and keep them in a safe spot away from your flailing legs and arms. 
• From the gas filler area outside the van, pull the filler neck up-and-out. 
• Unplug the wires to the fuel level sender unit and your tank will now be free to drop. 

Now's the time to get after all the vapor hoses and grommets in the tank. Our kit includes vapor lines, grommets, and a new crossover pipe. Don't forget to replace your filler neck seal and fuel level sender unit seal as well. It can take some wrangling to install the grommets - sometimes it's easier to remove the grommets from the hose, install them into the tank body and then reinstall the hose. 

Reinstallation is the opposite of removal. Take your time and make sure everything is attached and all connections are tight. Don't forget to plug in your fuel level sender wiring - you don't want to have to drop the tank again because you forgot to do so. Clean up all fuel and change out of your gassy clothing before reconnecting the battery. Keep an eye (and a nose!) on your newly sealed tank for the next while until you're sure that everything was re-sealed correctly. Enjoy your new peace of mind! 

Working on vehicles carries an inherent risk. Work on your van at your own risk. Van Cafe accepts no liability or responsibility for your actions or their outcome. Please be safe and use your head! 

Back to Vanagon Knowledge Base