Club 80-90 Forums

Well I finally got around to dropping the tank.

Shepster had it nailed, the piping was not too bad, the leaks were coming from the grommets and fuel sender.



You can see where the leaking fuel has washed off the underseal that was applied to the tank.





Signs of leakage from around the fuel sender and gromments.

The grommets that I removed don't look too bad, I suspect that they were badly installed.

I have a load of photos and can write a small how to for the WiKi if people think it's worth it.

Cheers
TAD

To be frank I think VW let themselves down in terms of safety in this area. My biggest gripe is the large bore crossover pipe which allows communication between the high points either side of the tank. I believe the design intent is that all of it should be the highest point in the system else you won't get a full tank. In my van at least it is a plumbers nightmare and impossible to visually inspect once the tank is up. In this respect only I envy owners of diesel vans.
CS

Citizen Smith wrote:To be frank I think VW let themselves down in terms of safety in this area. CS

If think that VW have a very good understanding of what is safe, besides these vans were not designed to last 20 odd years.

how to would be fab Mr Duxass!

ermie571 wrote:how to would be fab Mr Duxass!

Well I tanked last night and there was a very small amount of leakage dripping from the right hand side of the tank.

I suspect that it is the O-ring seal for the fuel level sensor, it looked okay but.....

Can someone give me the part number?
I've look at both my online catalogues and they both have no details of either level sensor or its O-ring seal.

Titus A Duxass wrote:Well I tanked last night and there was a very small amount of leakage dripping from the right hand side of the tank.

I suspect that it is the O-ring seal for the fuel level sensor, it looked okay but.....

Can someone give me the part number?
I've look at both my online catalogues and they both have no details of either level sensor or its O-ring seal.

113 919 131 A

Available on Brickwerks: https://www.brickwerks.co.uk/fuel-level ... l?___SID=U

jamesakers wrote:

Titus A Duxass wrote:Well I tanked last night and there was a very small amount of leakage dripping from the right hand side of the tank.

I suspect that it is the O-ring seal for the fuel level sensor, it looked okay but.....

Can someone give me the part number?
I've look at both my online catalogues and they both have no details of either level sensor or its O-ring seal.

113 919 131 A

Available on Brickwerks: https://www.brickwerks.co.uk/fuel-level ... l?___SID=U

Danke!

Lubricate the sender seal with graphite to stop it rucking up. But the fuel sender is on the left of the tank.

bigherb wrote:Lubricate the sender seal with graphite to stop it rucking up. But the fuel sender is on the left of the tank.

Good tip, it looks quite inadequate for the job.

bigherb wrote: But the fuel sender is on the left of the tank.

I know, this is just my gut feeling.
I'll have a closer look with a torch this evening.

On one of the online parts catalogues that I use shows some of the tubing connections secured with one ear clamps.

Titus A Duxass wrote: Good tip, it looks quite inadequate for the job.
.

The problem is the pattern replacement tanks which are thinner gauge steel doesn't pull the seals down as tight.
The sharper and sometimes irregular edges also need dressing to stop cutting into the seals.

bigherb wrote: The problem is the pattern replacement tanks which are thinner gauge steel doesn't pull the seals down as tight.
The sharper and sometimes irregular edges also need dressing to stop cutting into the seals.

We've got some POL resistance rubber sheeting that we use for seals, I'll cut a ring out glue it to the painted surface of the tank.

1.6 JX TD
After fitting new power steering pipes my fuel tank leaked when filling up full. I dropped the tank and found it in excellent condition but the breather pipes had popped out - maybe when I was fitting the power steering pipes. I just painted the tank, fitted new rubber breather tube ... and it still leaks. A big leak - like all over garage forecourt. Very embarrassing. I've felt the grommets and they seem to be in place. I guess the grommets and seals were in poor shape and didn't like refitting so I've just ordered new grommets and fuel level sender O-ring...

jhobson wrote:.. so I've just ordered new grommets and fuel level sender O-ring...

I dropped my tank again, this time I replaced the Sender O-Ring and clamp all the hoses with single-ear hose clips.
I have yet to fill up the tank to see if it was a success.

I'm in the process of replacing the tank on mine after the old tank leaked. On removing the old tank I found tiny pin holes on the top left corner, it looks like the wiring loom has sat against the tank here and rubbed through the paint. The holes were hard to spot so if you're planning to keep your old tank in there give it a thorough inspection.

I've got new grommets x 3 for the breathers, a new filler neck seal and new 5.5mm fuel line for linking the breathers, I think I'll add clamps on those joins too. I'm reusing old sender seal as recommended by Brickwerks. All the grommets/seals will be refitted with a very light smear of hylomar blue, seems daft not to really.