> 1a) did you put the gromets & filler gasket on the tank first then slide 
> the
> vent lines in
> what did you coat the filler pipe with so it slides into the new filler
> gasket ?
> 

I fitted all the grommets on the tank first out in the daylight where I 
could see them. I liberally coated all the grommets with Teflon gel 
lubricant and everything went in smooth and easy. The tube I have is from 
Radio Shack (part# 64-2326) and labelled "Lube Gel", but it's sometimes hard 
to find as not all RS stores carry it. Their web site says it goes for a 
mere $1.97, so that's the cheapest source I know of. It's also available 
other places under the brand name "Super Lube" <http://tinyurl.com/bjp5u>, 
but tends to go for 4 to 5 bucks a tube. It feels similar to Vaseline, only 
it's odorless, tasteless, and completely inert. Rubber parts absorb it 
readily without ill effect, so it's really good for slipping on coolant 
hoses, door rubber, and grommets. After the part slides on, the gel 
disappears into the pores of the rubber. It's actually pretty good for 
reconditioning rubber parts that are getting hard and dry. I turned a dry, 
stiff wing window rubber gasket set that was getting that gray streaky look 
into soft, glowing, shiny black rubber with this stuff. Supposedly you can 
also use Vaseline for all these things just as well, but I don't much care 
for its petroleum smell. 

Anyway, coming back to the subject at hand: I put in the tank with the 
grommets already in and just coated all the plastic parts that go in the 
grommets with Teflon gel. That or Vaseline ought to do the trick. Filler 
tube, vent tube, and that crossover tube with the two barbed fittings will 
pop right in.

-- 
John Bange
'90 Vanagon
"Keine Bange, wir holen die Zange!"