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Injection tank removal
Posted: 16 Feb 2018, 17:28
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.
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.
Re: Injection tank removal
Posted: 16 Feb 2018, 18:13
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.
Re: Injection tank removal
Posted: 16 Feb 2018, 18:30
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

the great thing about drill bit shanks is everybody has a range of sizes readily available
Re: Injection tank removal
Posted: 17 Feb 2018, 17:20
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 ?
Re: Injection tank removal
Posted: 17 Feb 2018, 17:29
by 300CE
When the tanks out Paul, give the area a good clean and coating of dynax/waxoyl before refitting

Re: Injection tank removal
Posted: 17 Feb 2018, 17:53
by 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
Re: Injection tank removal
Posted: 17 Feb 2018, 18:00
by 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
Re: Injection tank removal
Posted: 17 Feb 2018, 18:16
by 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
Re: Injection tank removal
Posted: 17 Feb 2018, 18:17
by 300CE
Looking good sir - did you notice if any of the pipes were perished?
Re: Injection tank removal
Posted: 17 Feb 2018, 18:21
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
Re: Injection tank removal
Posted: 17 Feb 2018, 18:31
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.
Re: Injection tank removal
Posted: 17 Feb 2018, 18:45
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.

Re: Injection tank removal
Posted: 17 Feb 2018, 18:47
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.
Re: Injection tank removal
Posted: 17 Feb 2018, 18:53
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

Re: Injection tank removal
Posted: 17 Feb 2018, 19:01
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
P1090604 by
Paul_Barr, on Flickr