Injection tank removal

Big lumps of metals and spanners. Including servicing and fluids.

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itchyfeet
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Injection tank removal

Post by 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.

ImageP1090555 by Paul_Barr, on Flickr

ImageP1090557 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

ImageP1090556 by Paul_Barr, on Flickr

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

ImageP1090558 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

ImageP1090559 by Paul_Barr, on Flickr

got dark continue tomorrow.
Last edited by itchyfeet on 16 Feb 2018, 18:31, edited 1 time in total.
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Oldiebut goodie
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Re: Injection tank removal

Post by Oldiebut goodie »

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

Post by itchyfeet »

Oldiebut goodie wrote: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 :ok
the great thing about drill bit shanks is everybody has a range of sizes readily available
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937carrera
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Re: Injection tank removal

Post by 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 ?
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300CE
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Re: Injection tank removal

Post by 300CE »

When the tanks out Paul, give the area a good clean and coating of dynax/waxoyl before refitting :ok
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

Been at this all day :roll:

breather off the filler

ImageP1090564 by Paul_Barr, on Flickr

filler neck off and pulled the filler out

ImageP1090566 by Paul_Barr, on Flickr

breather pipes off breather tanks

ImageP1090569 by Paul_Barr, on Flickr

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

ImageP1090571 by Paul_Barr, on Flickr

made a support for the tank

ImageP1090573 by Paul_Barr, on Flickr

strap bolts off

ImageP1090575 by Paul_Barr, on Flickr

lowered it a bit and all three breathers off tank

ImageP1090578 by Paul_Barr, on Flickr

ImageP1090584 by Paul_Barr, on Flickr

sensor wire off

ImageP1090583 by Paul_Barr, on Flickr

dropped it

ImageP1090585 by Paul_Barr, on Flickr
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

no large rusty holes :ok

ImageP1090590 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

ImageP1090591 by Paul_Barr, on Flickr

this is the worst rust

ImageP1090592 by Paul_Barr, on Flickr

cleaned it and added vactan

ImageP1090594 by Paul_Barr, on Flickr

ImageP1090596 by Paul_Barr, on Flickr

undercoat

ImageP1090601 by Paul_Barr, on Flickr

top coat

ImageP1090603 by Paul_Barr, on Flickr

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

ImageP1090600 by Paul_Barr, on Flickr


new filler seal in

ImageP1090599 by Paul_Barr, on Flickr

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

ImageP1090602 by Paul_Barr, on Flickr

cleaned and treated the rust underneath

ImageP1090604 by Paul_Barr, on Flickr

ImageP1090606 by Paul_Barr, on Flickr
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

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

ImageP1090614 by Paul_Barr, on Flickr

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

ImageP1090617 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

ImageP1090620 by Paul_Barr, on Flickr

breather pipe back in

ImageP1090623 by Paul_Barr, on Flickr

tank under

ImageP1090622 by Paul_Barr, on Flickr

lifted a bit and sensor connector on

ImageP1090625 by Paul_Barr, on Flickr

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

ImageP1090633 by Paul_Barr, on Flickr

tanks straps on

ImageP1090635 by Paul_Barr, on Flickr

just about to put the tanks back when I found this :shock:

ImageP1090637 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

ImageP1090640 by Paul_Barr, on Flickr

tanks and filler back in

ImageP1090647 by Paul_Barr, on Flickr

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

ImageP1090650 by Paul_Barr, on Flickr


ImageP1090651 by Paul_Barr, on Flickr

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

ImageP1090652 by Paul_Barr, on Flickr
Last edited by itchyfeet on 17 Feb 2018, 18:19, edited 2 times in total.
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300CE
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Re: Injection tank removal

Post by 300CE »

Looking good sir - did you notice if any of the pipes were perished?
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

300CE wrote: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
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300CE
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Re: Injection tank removal

Post by 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.
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Oldiebut goodie
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Re: Injection tank removal

Post by 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. :D
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937carrera
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Re: Injection tank removal

Post by 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.
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

937carrera wrote: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 :ok
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itchyfeet
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Re: Injection tank removal

Post by itchyfeet »

937carrera wrote: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

ImageP1090604 by Paul_Barr, on Flickr
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