Fuel Tank Reseal (2WD)

Fuel Tank Reseal for 2WD vans:

Smelling fuel from your Vanagon when you're refueling? 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

and expansion tanks, filler neck hoses and O-rings and 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


You'll need our fuel tank reseal kit and a filler neck seal. You'll need a 13mm socket and ratchet, various

pliers and 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. Don't put any upward pressure on the tank - we're not lifting 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 sender and your tank will now be free to dropdown.

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 sender 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 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. Rocky Mountain

Westy accepts no liability or responsibility for your actions or their outcome. Please be safe and use

your head!