Syncro fuel tank removal

[Gordo_89]

I recently did the fuel feed and return lines on the syncro however I think the vent lines need some attention now. Does the engine need to be removed to get the fuel tank out?

I am currently in the process of removing the gear box.
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1989 Vanagon 2.1L

[Syncro Jael]

I unplugged my vent line to the charcoal canister and blew carburetor cleaner through the lines, followed with compressed air. It really did help it breathe when fueling the van now. It could save you from pulling the transaxle.

From my remembering the fuel tank should be able to come out with the engine still in place. But I have never done this.

Cheers
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1987 Syncro Westfalia Hightop - NAHT
Subaru EJ25 Forged Frankenmotor, Triple Knob.
Jael = (Mountain Goat)

[Gordo_89]

The vent lines look perished, so looks like Im committed now. See what the damage is once I get it down. That's if it drops down ok. The euro model doesn't seem to have a charcoal canister either.
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1989 Vanagon 2.1L

[flomulgator]

I have removed and reinstalled the syncro tank with an engine still in the vehicle.
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She's built like a steakhouse, but she handles like a bistro!

[Gordo_89]

[flomulgator]

Look for threads on how to remove the transaxle without the engine, there has to be a guide somewhere. Maybe check the FAQs sticky. An engine crane was still involved for me.
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She's built like a steakhouse, but she handles like a bistro!

[Bassyaks]

Worst Job EVER!!! since you have it out replace everything, including mounts, all lines, grommets. You'll regret it if you don't

[MarkWard]

I just finished converting a 2wd to Syncro. For the entire project, I had the engine and transaxle assembled together. I had them in and out 3 or 4 times before the final assembly.

There are 2 bolts at the front of the transaxle and 2 bolts on each end of the carrier bar. That’s all that holds it. I did not have to deal with coolant lines or the engine harness though.

No doubt after you have done one, you could do it with only the transaxle removed, but the tank does not drop out or slip in. There is one position it needs to be in. The tip I used was a thin piece of ABS plastic between the fuel sender and the frame rail. It still required some prying.

If you don’t have a charcoal canister, all Syncro vans came with an extra hole in the sheet metal and the filler housing where the tank vent followed the overfill line up into the filler housing where it is looped and vents to atmosphere. That is how I did mine for when I convert to diesel power.

Where safety glasses and have patience. While it appears there is no way it will come out. Find that angle and with some mild prying it will come out. It takes more prying than a technician would feel comfortable doing. To a point, the tank is slightly flexible.

Good luck.

[OldBlueSyncro]

I did this last summer. I first just removed the transaxle. I started cleaning up the rust between the body and fuel tank for painting. There was no room to work down there with the engine still in so I ended up removing it as well. POR-15'd everything down there, then reinstalled the transaxle and engine while they were assembled together.

If I was to do it again, I would remove the engine and transaxle together to begin with. Gives you more room to work and I honestly think it's easier.

Also, be careful not to damage the bottom outlet on the fuel tank. I hear stories of them cracking.

[Gordo_89]

finally the tank is out!

The larger line was in a poorer condition of the two and the vent was also broken, either in removal or previously

looks like i need new tank straps too.
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1989 Vanagon 2.1L

[MarkWard]

[Gordo_89]

Yes just the transaxle removed although for the amount of stuff that needs removing you would probably be just aswell dropping the lot.
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1989 Vanagon 2.1L

[Gordo_89]

so fuel tank is out and one job leads to another and another.....

what solutions are there for the metal work. looking to wire brush it all and coat it up with a rust treatment possibly followed by a waxoyl.

i will probably continue down the chassis as the stuff put on has loose edges and the black stuff underneath scrapes off pretty easily (possibly the original coating ?)

i can see the light under the van
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1989 Vanagon 2.1L

[flomulgator]

While I pulled the tank to service it thinking there were a bunch of issues, it turns out I had a few more years of life left in most of the parts. I was almost annoyed until I saw the rust above mine and then was glad I pulled it (still very happy to have all new fuel parts). I used various wire and grinder rust removing techniques, then followed up with Ospho (a phosphoric acid product). That converted any rust I couldn't reach and gave anything I stripped to bare metal "bite" with an acid etch. For this job I followed up with POR-15, but I've also become a fan of the very similar Rust Bullet after that job. Once that had cured, I sprayed everything with a rubberized underbody coating to dampen sound without absorbing water.

Take a close look at the inside of the rear strut towers, could be rusty and easy to miss. Wear a respirator and face shield while grinding and applying chemicals in that semi-enclosed space.
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She's built like a steakhouse, but she handles like a bistro!

[Sodo]

For those who need to do this project.....

a shop VACUUM shrinks the Syncro tank!

Corey Patterson at PeaceVans told me that he tested sucking a vacuum on the Syncro tank with his shop vacuum. He said you can see the tank shrinking smaller. He plugged all the vent hoses and the outlet, and his vacuum hose inserted into the filler donut as if it was meant to be. Corey said its easy to move the tank in & out of the space with a vacuum.

This is really great news, to have a tank that carries as much fuel as possible, but having a method to shrink it for service.

See "more discussion" on other thread called "Syncro Gas Tank rebuild"
https://www.thesamba.com/vw/forum/viewtopic.php?p=10351983#10351983
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Steve Arndt]

Be careful there are no fuel fumes going through a shop vac.
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Steve
Steve's 87 Syncro project