Club 80-90 Forums

Is there a detailed guide available for replacing a fuel tank (petrol, dg)? I've read the wiki re removal and also have the Haynes manual. It's just things like removing the filler from the tank etc.

I did this last week. Found refitting it a bit difficult as:

A) The clip which screws into the floor to hold the large top tank breather hose in place prevented me from being able to push the breather pipe back into the grommets into the top of the tank from either side of the wheelarch. Ended up leaving that clip off as the breather hose isn't going anywhere.
B) I haven't exactly got spade hands but having the hands of a baby would be useful, reaching in small spaces to connect stuff back up.

The filler is easily removed. Unscrew the screws around the filler cap then remove the jubilee clip that holds the filler hose onto the plastic elbow (may just break off if rusty). Pop the filler pipe off that end. The breather pipe that goes to the tank, you should have just enough room to get your hand in and waggle it loose from the grommet on top of the fuel tank...unless the breather has already come detached from the filler pipe like it had on mine. In that case, remove it after dropping the tank. You can then waggle the filler pipe out of the tank as it is only a push fit through a grommet.

The breather tank hoses can be simply pulled off.

Do a search on vw t25 tank removal on the internet and there are lots of pics with the tank off but with all ancilliaries connected. Helps you to see how its all connected on the van.

Good luck

did my injection tank recently, almost identical to a DG tank, just the fuel outlet is bigger

shows removing filler, the plastic moulding to the body rotates to remove

https://club8090.co.uk/forum/viewtopic.php?f=37&t=163356" onclick="window.open(this.href);return false;

Thanks alot for the input, very helpful

Just incase anyone wants more of an indepth guide, found this very helpful article written by a member on here I think? :

https://vwt25.blog/2016/05/03/replacing-the-fuel-tank/

Did mine within living memory. Its very straightforward. Front on axle stands or ramps - trolley jack to lower it. Great excuse to clean up and treat the underside too

https://www.youtube.com/watch?v=ziAmP7y9Psk" onclick="window.open(this.href);return false;