Yup!  I believe you have stumbled across a common problem.  Running over the
tank is a plastic hose that has a "Y" connector on each end.  The bottom part of
this "Y" goes into the gas tank.  This hose resembles the hard plastic hose you
typically see used on brake boosters.  The "Y" connectors crack over time.  So
when you fill the tank completely, fuel overflows out.  By the way, this hose is
used for ventilation.

The bad news is that you must drop the tank to replace it.  The hose is attached
to the frame by a clamp in the middle of the hose, which is almost two feet
long.  The "Y" goes into the tank through a rubber grommet that gets very hard
with age.  If you look at your tank from both sides of the car, just in front of
the front tires, you can see the hose.  When removing the tank, you must pry out
the "Y" first (because of the clamp attached to the frame).  In most cases, they
are partially or completely cranked anyway, so the hose comes out with the tank.

The dealer is the only place I know of that sells this hose, and since it is
like the brake booster hose (heat shrunk on the "Y" connectors) they sell the
hose and each "Y" as one piece.  Also, be sure to buy new grommets, very
important to make installation easy.

When you install the hose, grease the bottom of each "Y" and the new grommets
you replaced, then clamp in the hose and connect the ventilation hoses.  Install
the tank.  Then reach in just in front of each front tire and pop in the "Y"
connectors.  This is when the grease on the fittings comes into play, because
the fittings will pop right in with a little bit of force.

Good luck!

Z

Ezra Hall <ehall@TOGETHER.NET> on 03/08/2000 12:59:59 PM

Please respond to ehall@TOGETHER.NET

To:   vanagon@GERRY.VANAGON.COM
cc:    (bcc: Zoran Mladen/AMS/AMSINC)
Subject:  Fuel leaks/smell

  Since purchase last Sept, we have had a gasoline smell problem after fill up,
especially when filling the tank all the way. I see the filler neck leaks
towards
the opening, so that needs replacement or repair. However, even after driving
for a couple of hours, gas can be smelled when the doors are opened. I assume
I need to drop the tank to find the source of the leak. I would like to minimize
down time, are there common seals that need replacement so I can order prior
to dropping the tank? Hopefully we don't have rust holes on the top of the
tank...
Other than the filler neck, there are no visible leaks from below.
Thanks,
 Ezra Hall
www.together.net/~ehall
'88 westy, Automatic