Gas Tank Install Tips

[sdyck]

So my tank has been boiled out, POR15'd and ready to install.    I have new fuel sending unit, new filler neck, new vent and fuel lines on order (Should get them from GreenLine Hose early next week).

 

So I was wondering if anyone had any tips to help with the install.  All those damn hoses are going to be a pain to hook up.  I'm figuring I'll put the fuel filler, the vent tank lines in place and then with the tank supported, but not all they way up start with the fuel in and out lines as well as the fule filler neck and work my way around on the vent lines.

 

I remember when I dropped the tank, getting to some of the clamps and pulling the lines off was really tough so any hints would be appreciated.

 

Thanks,

 

Steve

[jfa.series1]

Nice paint job.  You're pretty well on track with a sequence.  The new filler neck should be first, then the vent lines to the collection tank.  Position the tank as you said and connect the two topside vent lines visible in your photo.  Work the tank into position (a floor jack works well) and mate it with the filler neck - don't forget to pre-position the clamp.  A bit of grease inside the filler neck really helps.  If the new filler neck is too tight, warm it with a heat gun.  Finish getting the tank up and secure it with the straps.  The small vent and fuel lines on the front can be handled last.

 

I did all this solo on my back until mating the filler neck.  A neighbor help stabilize the tank while I fought it into position.  So...an extra set of hands can help a lot and getting the car on a lift is a bonus!  Good luck.

[hatepotholez]

Steve,

 

I just went through the fuel tank install. Man was it a pain! Ok this is what I did:

 

I did mine on the floor with no lift, just jack stands.

 

1. put blankets or cardboard on the floor and underneath the tank so the jack stands don't scratch it.

2. make sure all your grommets are in place.

3. connect all the hoses to the tank and route them through the correct openings(longest hoses).

4. guide the fuel sending unit harness near the sending unit, don't connect it at this point just put it out of the way.

5.Tighten the hose across from the fuel return and sending lines.

6. attach the bands to the rear of the vehicle(not the J bolt ends) and support them while hanging.

7.use a little soapy water on the main filler neck and attach it to the tank with the clamp.

8. Have someone hold the tank up while you install the main filler neck, or use jack stands to hold the fuel tank up.

9. attach the other end of the band(j bolts)

10. tighten and connect all the hoses.

11. tighten the j bolts.

12. connect the fuel harness.

 

I'm pretty sure I am missing something but I hope this is helpful.

[Travel'n Man]

Replace every line you can while you have it out - and the grommets in the back hatch area - and the grommet under the vapor tank -

• Did you replace your vapor hoses while you were at it?

[grannyknot]

Don't forget the rectangular pads that isolate the tank from the car body, glue or tape them to the tank before raising it.

[bartsscooterservice]

It's a pain yup. Need to do it with 2 people imo easier install.  1 has to go under the tank ( lay on his back ) and raise it accordingly ( jackstand is not so handy, only to support if half way ) while the other one connects everything.  Connect the vent hoses first, then the filler neck. The filler neck is the hardest part to go on, like suggested if it's to tight, heat it up a little or use a little bit of soap on the inside for install. ( remove the little plate on the right rear wheel housing to get better acces to the filler neck ).

 

The fuel sender cables and the fuel lines to the front can go on when it's all installed.

[sdyck]

Thanks that is a great help. I was planning on cajoling everything Ito the vent tank first and then working on the gas tank. Now I see if I do the gas tank first I'll have some more play to work with.

Yes I have all new vent lines and fuel lines. I ordered some hard wall marine fuel lines for the 5/8" vent line that is nla.it has a 2" bend radius, so I'm hoping there's enough room to make the 180 degree bend. If not I will use copper fittings.

my wife isn't patient enough to offer another set of hands so I'll see if my 11 year old will be of any use.

Thanks again

Steve

[bartsscooterservice]

Haha ok   I used a plastic 180 degree that could resist fuel ( don't know the english name, pvc ? ), because of weight. 

Raise the tank half way and connect all the vent lines first to the tank, then you can move on to the filler neck and raise the tank accordingly. Make sure no vent lines are jamming when you work it up.

[bvolken]

A transmission jack is super helpful.  I used a spring to make the 180 degree bend.  Also found nice oem-looking braided fuel lines from a volkswagen supply store.

Fuel Tank Refresh.  Lots o' photos.