Steve,

Across the top of the tank, at least on my 84 Westy, there is a Rube
Goldberg arrangement of a horizontal pipe which connects to the fuel
expansion tanks at the top of the wheel wells. Support the van so that
the wheels drop. ( In old, dirty clothes,  you'll get filthy at this
exercise) reach up to feel the horizontal pipe and, especially a "Y"
connector at each end of the pipe which connects to a line to the
expansion tank.   It is this "Y" which fails routinely in the Vanagon.
The pipe can be replaced WITHOUT removing the gas tank, which the dealer
will say is necessary.  ( I have done it.) The part is about $27.00 US.
If the failed part is the Double-ended-"Y"" connector pipe, let me know
and I'll give you the technique to replace, which involves digital
dexterity,  removing the spare tire carrier and fiddling with the clamps
on the pipes.

Too, the cause could be the grommet at the filler pipe to the tank, or
breaks in other small expansion lines.  If it is the filler neck
grommet, it appears to be a tank removal job.

We limped along for years by filling the tank with 10 US gallons very
200 miles, or so.

There is ample information in the archives on this topic.

Tom Hanlon
Palm Springs, CA
1984 Westfalia

Steve Macaulay wrote:

> My 1989 Westy leaks gas when the tank is completely filled.  I've been
>
> dealing with this problem for the couple of months I have had this van
> by
> trying to not rely on the auto-stop feature of most gas nozzles and
> estimating about how many gallons to add to get it close to filling up
>
> without overfilling.  I'm getting better at this, but when I'm wrong I
> have
> a slow but steady dripping of gas until I drive it around for a few
> miles.
>
> Anyone experience a similar problem and have any suggestions?  I plan
> on
> having the dealer look at this when I get my 60000 mile checkup in a
> few
> thousand miles, but I'm wondering if this is a common and relatively
> minor
> problem that I might be able to correct myself.  I've noticed from the
> VW
> FAQ that there have been several fuel tank related recalls for 80s-era
> VWs
> (not just vanagons), but there doesn't seem to be one for my 1989
> year.
> Although I haven't checked this out thoroughly, a quick check of the
> visible
> fuel tank components didn't shed any light on the problem, although it
> may
> have if it was leaking at the time.
>
> Thanks,
>
> Steve
>
> 1989 Westy