Visible Gas Leak

[jpcrane]

I just bought this bus a few weeks ago. A fuel injected 1977 Westfalia. The PO said he never fills it up all the way because if he does it smells like gas. I wanted like to see what kind of mileage I'm getting and I plan on going on some longer trips where a full tank of gas would be handy so I decided to fill it all the way up. I was expecting to smell some gas (as the PO described), I was not expecting to hear gas pouring onto the ground.

After the gas pump automatically stopped (the tank was full), I quickly opened the engine door and was able to see where the gas was coming from (picture attached). The picture is of the left rear of the engine compartment. The gas was coming from where the gray hatch meets the orange (shiny from the gas). I waited a couple of minutes and the gas is no longer leaking.

So, I have a couple of questions:

1. Has anyone had this happen before and can tell me what I need to do to fix it? and how big of a project $$ it is?
2. Since the gas is no longer leaking is it ok to drive home (its currently as the gas station, I did start it up to move it to a parking spot - fire extinguisher in hand) without any problems.

Any advice would help, I'm a newbie!

Thanks! Justin

[JDub113]

I would not drive it until you replace the gas line from the tank to the filler tube. Might as well replace the rubber behind the gas cap too. Do a quick search on gas lines and you'll see a diagram so you can identify and replace all the breather line sections as well.

You'll need to pull out the grey firewall panel and I hear its a PITA, but you can get in there to replace both rubber pieces.

I posted about this not long ago.
http://www.thesamba.com/vw/forum/viewtopic.php?t=5...highlight=


http://www.thesamba.com/vw/forum/viewtopic.php?t=598324&highlight=gas+lines
_________________
84 Wolfsburg Edition Westy

[busdaddy]

I wouldn't drive it either, call a tow truck if it's close to home.

Sounds like you'll be pulling that grey panel off and replacing the filler elbow (#1) as well as the lower tube (#6) and all the little connector lines (#24) in there.

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[udidwht]

That's on the drivers side. It is also an evaporative section of fuel line that is the cause if filled to full. I'll bet when you filled the bus was also leaning more on the drivers side as opposed to the passenger side?

VW did NOT use hose clamps on any of the small sections of fuel line behind the firewall. If you replace them feel free to do the same just make the new pieces a bit longer than the old ones.

Don't be surprised if you find that the new ones do the same if over filled. Don't worry, quite common.
_________________
1972 Westy Hardtop/Type-4 2056cc
96mm Biral AA P/C's~7.8:1CR
Headflow Masters New AMC 42x36mm heads w/Porsche swivel adjusters
71mm Stroke
73 Web Cam w/Web solids
Dual 40mm IDF Webers - LM-2 - 47.5 idles/125 mains/190 air corr./F11 tubes/28mm Vents - Float height 10.45mm/Drop 32mm
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Bosch W8CC plugs
Pertronix Flamethrower 40K coil
S&S 4-1 w/Walker QP 17862
3 rib 002 Trans
185R14 Hankook tires

[jpcrane]

Thanks Everyone! I went back though my notes etc. from the PO and he said that he replaced all the hoses and other "gas related components" except the fuel gauge sender seal. He has receipts from several components. Could the sender seal be what is causing the leak?

Is the gauge sender seal reachable through the grey panel?

Also, where is that great diagram from?

Thanks, Justin

[jpcrane]

[Wildthings]

You are going to need to pull the firewall and see where the leak is. Anything less is just worthless speculation. That said, it is very common for the short hose sections connecting the various steel vent lines to leak, I wouldn't put much weight in receipts and such from the PO, the van is yours now and you need to check every part as you go.

All the vent hoses and filler hose pieces were shot on my '74 Bay 20+ years ago. I find it amazing that so many people still try to get more mileage out of these same badly aged parts.

[encsdaddy]

Also post your location in your signature line. You may find that you have some members close by who can help.
_________________
77 Westy named Tiki - Daily Driver 80 miles a day!
(2.0L with hydro lifters)
78 Bus (8 seater w/ front bench) - Still trying to get it running! (fuel pump cuts out)
69 Sqauareback - RIP (Rear ended by a Volvo)
72 Bug - RIP (Rusted away!)

[Keith]

[jpcrane]

Hi Everyone,

I was able to take off the gray panel and find the problem (see pic)

I put on a new slightly longer hose and used a couple hose clamps just in case (I know, everyone says I don't need them, well the old hose came off!).

I'm not sure why my location didn't show up. I'll update my profile.

I'm in Cary North Carolina.

Thanks! Great forum!