I put in the new tank with a new sender as well, and had to tweak the tabs
on the tank opening before I could install the sender. It was too tight as
Joe discovered, and I also used silicone spray to lube the O-ring.

Neil, the crossover pipe goes over the coolant pipes, that's why it's a PITA
to do without dropping the tank down at an  angle, but not too steep an
angle.  It's intended to pass air, not fuel, between the two camel's humps
as the fuel sloshes around, and you don't want fuel trapped in it.

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Joe T.
Sent: Tuesday, March 12, 2013 9:49 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Gas leaking after filling to the top...84 2wd..

I just did this (again) a couple of weeks ago.

I did the reseal using the Van Cafe kit three years back, but didn't replace
the fuel gauge sender or, more importantly, the O-ring that seals it to the
tank.  Recently a massive leak developed there, and even if I filled up 3/4
full you could still smell gas around the driver's side.  On full fill-ups,
gas would visibly leak down from the sender area.  I also have been fighting
the buzzing fuel pump issue since I bought this particular Vanagon almost
eight years ago.

This time around, I decided to bite the bullet and go with the newer-style
tank with the larger outlet to the fuel pump, discard the plastic pre-filter
in favor of the big metal cylindrical after-pump filter, and replace the
sending unit and its o-ring completely.

I have to say that this is what I should have done last time.  The only
issue I had was getting the new sender into the new tank.  It was a bear to
get in, and I ended up shattering it into three pieces by trying to muscle
it too much with a big wrench.

Thankfully, there was nothing wrong with my old sender, and with a new
o-ring, it went in fine.  Although it sucks to watch fifty bucks shatter
into three pieces...

I'm happy to report no constant gas smell, full fill-ups, and a nearly
inaudible fuel pump.

>
> --
> Joe T.
> '85 Wolfsburg Westy Subie 2.2