Volkswagen Air Cooled 1949-1969 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Type 1 and 3 Models


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Fig. Fig. 1 Cross-sectional view of the boot for the fuel tank breather pipe



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Fig. Fig. 2 To remove the fuel tank, detach any hoses from the tank ...



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Fig. Fig. 3 ... then remove the fuel gauge cable/sending unit cover



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Fig. Fig. 4 Detach the cable from the sender by sliding the ball (arrow) out of the lever housing



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Fig. Fig. 5 Remove the four hold-down bolts and brackets ...



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Fig. Fig. 6 ... then lift the tank up and out of its recess



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Fig. Fig. 7 To remove the sending unit, detach the cable and remove the 5 retaining screws ...



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Fig. Fig. 8 ... and lift the unit out of the tank



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Fig. Fig. 9 Make certain to replace the old gasket with a new one prior to installation


CAUTION
Gasoline vapors are EXTREMELY volatile. To prevent the potential danger of spilled gasoline, drain the fuel tank with a hand pump siphon prior to removal. When servicing the fuel system: extinguish all open flames, do not smoke, have a fire extinguisher handy at all times, and always ensure proper ventilation of fresh air in the service area.

  1. Disconnect the negative battery cable.
  2.  
  3. Using a small hose clamp, squeeze the rubber fuel line shut between the fuel tank and the metal fuel line. Detach the rubber fuel line from the metal one.
  4.  
  5. If equipped, remove the luggage compartment fiberboard liner.
  6.  
  7. Label and detach all wires from the fuel gauge sending unit.
  8.  
  9. Disengage the fuel vapor ventilation hose from the fuel tank connection.
  10.  
  11. Detach the fuel filler hose from the fuel tank neck by loosening the metal hose clamp.
  12.  
  13. Remove the four fuel tank retaining plate mounting bolts, remove the retaining plates, then lift the fuel tank out of the vehicle. It is good idea to have an assistant help lift the tank to prevent personal injury or fuel spillage.
  14.  


WARNING
When lifting the fuel tank out of its recess, take care not to damage the rubber sealing strip.

  1. Installation is the reverse of the removal procedure. New hose clamps should be used on the ventilation hose and the hoses should not be bent, twisted or kinked during installation.
  2.  

The newer type fuel tank can be installed in earlier models.

Type 2 Models

CAUTION
Gasoline vapors are EXTREMELY volatile. To prevent the potential danger of spilled gasoline, drain the fuel tank with a hand pump siphon prior to removal. When servicing the fuel system: extinguish all open flames, do not smoke, have a fire extinguisher handy at all times, and always ensure proper ventilation of fresh air in the service area.

  1. Disconnect the negative battery cable.
  2.  
  3. Except on pick-up truck models, remove the engine from the vehicle as described in of this guide.
  4.  
  5. On fully-enclosed models manufactured after May of 1968, remove the engine compartment front panel retaining screws, then lift the panel out of the vehicle.
  6.  
  7. On pick-up truck models, remove the retaining screws from the two tank compartment cover panels. Remove the panels from the side of the truck.
  8.  
  9. Using a small hose clamp, squeeze the rubber fuel supply line shut, then detach it from the metal fuel line.
  10.  
  11. Label and detach all wires from the fuel gauge sending unit.
  12.  
  13. If equipped, disengage the fuel vapor ventilation hose from the fuel tank connection.
  14.  
  15. Detach the fuel filler hose from the fuel tank neck by loosening the metal hose clamp.
  16.  
  17. Remove the fuel tank retaining strap mounting bolts, remove the retaining straps, then lift the fuel tank out of the vehicle. It is a good idea to have an assistant help lift the tank to prevent personal injury or fuel spillage. On pick-up truck models, remove the tank toward the cargo area, and on fully-enclosed models, remove the tank toward the engine compartment.
  18.  


WARNING
When lifting the fuel tank out of its recess, take care not to damage the foam rubber tank seal.

  1. Installation is the reverse of the removal procedure. New hose clamps should be used on the ventilation hose and the hoses should not be bent, twisted or kinked during installation. If the foam rubber seal was damaged during removal, replace it with a new one.
  2.  

 
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