I recently purchased an 85 GL with the similar problem of gas spilling out
on the drivers side while filling the tank.  Having owned American cars most
of my life, I suspected a broken overflow tube.  I was not prepared for the
many hoses and fittings on the Vanagon tank.  There are 4 grommets on the
tank.  One large one for the filler tube and 3 small ones for the others ie:
overflow, and some sort of venting for the charcoal canisters I believe.  I
talked to someone at my local VW "used parts" yard and he said it was a
common problem.  I glued the grommets to the tank with Hylomar HPF by
Permatex which I purchased at my local auto parts store.  It's supposed to
be impervious to gasoline.  I also coated the inside of the grommets with
the same before re-installing the fittings as well as the O-ring on the
sending unit.  I checked the plastic lines for cracks, etc. and they were in
fine shape.  I did replace the lines to the canisters.  I found out there is
a size of gas line between 1/4" and 3/16", it's metric, 5mm.  Nothing else
will work!  When I filled my tank up again, there was no leak what so ever.
However, when the nozzle cuts off, IT'S FULL!

This is not a procedure I would recommend to everyone.  After you empty your
tank from the outlet, there is still approximately 3.5 to 4 gallons of fuel
left in the tank.  Also, I still have a scar on my forehead from the tank
falling on it while attempting to re-install it.  This may be a 2 person
job.  Lastly, I was told the plastic lines and grommets were dealer items,
but you may be able to find them on line at the Bus Depot.  Luckily for me,
mine were still good.  I hope this helps.

Walter Evens
Hesperia, CA, USA
2-85GLs

----- Original Message -----
From: "Debra Clark" <debra_clark@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, February 10, 2002 8:48 AM
Subject: Gas overflow

Wow.  In my few short weeks of Vanagon ownership I have run head-long into
some common problems.  I hope this is the last one for awhile.  I searched
the archive for this problem and found some posts that were pertinent but
would like some more information.  On the last (and only fill-up), some gas
spilled out just prior to the pump automatically shutting off.  What is this
from?  How big a deal is this?

1990 Multivan

Debra Clark
Santee, California
debra_clark@yahoo.com