Injection tank removal

[itchyfeet]

I can't put this off any longer, it's fine in winter but there is a right old niff in summer while driving, I think fumes are coming into the fridge vents.

made a start today hopefully finish it tomorrow. I have a new piece of hose pipe for the tank to pump to fit also.

Everything I can see looks in good condition and no major smell outside I think the breather hoses are perished.

I'm struggling with a shoulder injury so I treated myself to a new Jack to make lifting easier and I have decided to use high density blocks rather than ramps, the ramps are wide so get in the way of the jack and these feel more stable on my drive.

I have had the jacking police giving me a dressing down before so please don't take my method of jacking as a recommendation and please don't bother complaining to me about safety, I'm happy with this.

P1090555 by Paul_Barr, on Flickr

P1090557 by Paul_Barr, on Flickr

I have run the fuel down but there is probably still 15l in there so I'm using an old 20l antifreeze container cleaned and dried, I have checked it's the same plastic as a fuel container and suitable.
I have a spare fuel pump so I borrowed the sealing cap to seal off the pump, pulled the pipe off and straight into the container

P1090556 by Paul_Barr, on Flickr

an old sump plug in the hole to stop any dirt getting in

P1090558 by Paul_Barr, on Flickr

pulled the return off the other side and with an old bit of pipe and a couple of drill bits sealed both pipes off

P1090559 by Paul_Barr, on Flickr

got dark continue tomorrow.

[Oldiebut goodie]

I don't waste drill bits - I use cut down round nails. Admittedly it is only 4mm hose that I plug regularly.

[itchyfeet]

I don't waste drill bits - I use cut down round nails. Admittedly it is only 4mm hose that I plug regularly.

How am I wasting them? they will still work when removed
the great thing about drill bit shanks is everybody has a range of sizes readily available

[937carrera]

Indeed, 8mm drill bits make an excellent replacement for many VW special tools.

How did you get on, did you have enough height to fully remove the tank holding brackets, or were you just wanting better access to replace the pipes ?

[300CE]

When the tanks out Paul, give the area a good clean and coating of dynax/waxoyl before refitting

[itchyfeet]

Been at this all day

breather off the filler

P1090564 by Paul_Barr, on Flickr

filler neck off and pulled the filler out

P1090566 by Paul_Barr, on Flickr

breather pipes off breather tanks

P1090569 by Paul_Barr, on Flickr

pulled tanks out, you don't need to but i want to inspect them.

P1090571 by Paul_Barr, on Flickr

made a support for the tank

P1090573 by Paul_Barr, on Flickr

strap bolts off

P1090575 by Paul_Barr, on Flickr

lowered it a bit and all three breathers off tank

P1090578 by Paul_Barr, on Flickr

P1090584 by Paul_Barr, on Flickr

sensor wire off

P1090583 by Paul_Barr, on Flickr

dropped it

P1090585 by Paul_Barr, on Flickr

[itchyfeet]

no large rusty holes

P1090590 by Paul_Barr, on Flickr

put the gromets back in with some pipe off cuts to stop dirt going in, rag in the main filler hole and gave it a good brush down

P1090591 by Paul_Barr, on Flickr

this is the worst rust

P1090592 by Paul_Barr, on Flickr

cleaned it and added vactan

P1090594 by Paul_Barr, on Flickr

P1090596 by Paul_Barr, on Flickr

undercoat

P1090601 by Paul_Barr, on Flickr

top coat

P1090603 by Paul_Barr, on Flickr

swilled the last bit of petrol aout with the dirt, did this a few times

P1090600 by Paul_Barr, on Flickr


new filler seal in

P1090599 by Paul_Barr, on Flickr

how was this ever a good place for the tank sensor earth?

P1090602 by Paul_Barr, on Flickr

cleaned and treated the rust underneath

P1090604 by Paul_Barr, on Flickr

P1090606 by Paul_Barr, on Flickr

[itchyfeet]

fitted all new rubber pipes , Brickwerks 100% ethanol pipe put it together just for interest to show how it fits

P1090614 by Paul_Barr, on Flickr

cut the ring off the sensor earth and had to cut it back a way to find good metal

P1090617 by Paul_Barr, on Flickr

added a new bolt driled in a new position because the old hole was very rusty and extended the wire

P1090620 by Paul_Barr, on Flickr

breather pipe back in

P1090623 by Paul_Barr, on Flickr

tank under

P1090622 by Paul_Barr, on Flickr

lifted a bit and sensor connector on

P1090625 by Paul_Barr, on Flickr

put the near side breather on but the offside needed to be done when tank fully up

P1090633 by Paul_Barr, on Flickr

tanks straps on

P1090635 by Paul_Barr, on Flickr

just about to put the tanks back when I found this

P1090637 by Paul_Barr, on Flickr

looks like they was drilled by Richard Holdsworth 30 years ago when something was riveted above, two in both tanks, may well have been the cause of the smell

P1090640 by Paul_Barr, on Flickr

tanks and filler back in

P1090647 by Paul_Barr, on Flickr

new 11mm pipe to pump on and reconnected return to tank

P1090650 by Paul_Barr, on Flickr


P1090651 by Paul_Barr, on Flickr

filled it up started it . checked for leaks and then lowered it.

P1090652 by Paul_Barr, on Flickr

[300CE]

Looking good sir - did you notice if any of the pipes were perished?

[itchyfeet]

Looking good sir - did you notice if any of the pipes were perished?

yeh the rubber breathers were perished but not holed, I think the holes in the breather tanks may well have been the issue

[300CE]

I’d put money on it being down to those holes. Do you usually fill the tank right up or to 3/4’s.

[Oldiebut goodie]

I have never dropped my tank but there must be an alternative way of getting of getting that 2nd breather pipe connection other than finding a dexterous midget. Is there any reason why that cross tank pipe has to be so taut that you can see? If an upward loop is necessary above the pipework it could be schemed with a greater length.
There may well be a reason that I am missing. Just musing as I see your hand disappearing into the bowels there.

[937carrera]

Great pictures as always.

One question - was the crosspipe from the left to the right hand side of the tanks secured to the floor or was it simply free. ? When I did mine there was a P clip, which just seemed an unnecessary inconvenience.

[itchyfeet]

Indeed, 8mm drill bits make an excellent replacement for many VW special tools.

How did you get on, did you have enough height to fully remove the tank holding brackets, or were you just wanting better access to replace the pipes ?

yes with this height the tank straps come off without bending the tabs

[itchyfeet]

Great pictures as always.

One question - was the crosspipe from the left to the right hand side of the tanks secured to the floor or was it simply free. ? When I did mine there was a P clip, which just seemed an unnecessary inconvenience.

yes there was a clip, dunno if it was in the clip before but I didn't bother putting it back, just see in in this pic

P1090604 by Paul_Barr, on Flickr