Katerina Swanson
Removing the fuel tank from a 68 VW bus is no easy feat. VW made engine removal harder in the 68-79 body design, and while it's possible to remove the engine and transmission as a unit, it's challenging to pull the engine off the transmission. Before removing the fuel tank, it's important to drain any fuel and clean the tank thoroughly. The filler neck, for example, should be inspected and replaced if necessary. To remove the tank, disconnect the wires from the fuel sender and unbolt the tank straps from underneath the body.
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What You'll Learn
Disconnect wires from the fuel sender
Disconnecting the wires from the fuel sender of a 68 VW Bus is a crucial step in fuel tank restoration or maintenance. Here is a detailed guide to help you through the process:
First and foremost, locate the fuel sender on the top of the fuel tank. The fuel sender is responsible for sending information about the fuel level to the gauge, and it is important to handle it carefully. To access it, you may need to remove any components blocking your path. In some cases, you might have to cut a small, accessible hole in the rear deck of the bus, just as some VW Bus owners have done.
Now, let's identify the wires connected to the fuel sender. Typically, you will find two wires attached to the fuel sender. One of these wires is a brown ground wire, which is usually screwed to the top of the fuel tank compartment to provide a ground connection for the sender. This ground wire is essential for the proper functioning of the fuel gauge. The other wire is also brown but is covered in a black plastic jacket. This wire leads from the fuel sender to a grommet hole at the back and to the right of the fuel tank compartment.
To disconnect the wires from the fuel sender, carefully unscrew the brown ground wire from its connection on the top of the fuel tank compartment. You may need to use a screwdriver to loosen any screws or clamps holding the wire in place. Once the ground wire is disconnected, turn your attention to the second wire. Gently pull or wiggle the wire to detach it from the fuel sender. Be cautious not to damage the wire or its surrounding components during this process.
After successfully disconnecting both wires, it is important to label or mark them for future reference. This will ensure that you can easily reconnect the wires correctly when reassembling the fuel sender. You can use tape or tags to label the wires, indicating their original positions and connections. By doing so, you'll make the reassembly process much smoother and reduce the risk of errors.
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Remove the gas cap and retainer ring
To remove the gas cap and retainer ring, start by removing the gas cap itself. Next, take off the retainer ring. It's worth noting that the filler neck is 25 years old, so even if it looks okay, it's best to replace it to prevent cracking after putting the tank back in. You can purchase a reproduction filler neck from any online VW parts vendor.
To remove the filler neck, first, remove the round black plate that covers the ECU. Then, remove the ECU to access the filler pipe more easily. Insert the new filler neck from the outside and remove it along with the pipe. Make sure to mark the position of the old filler neck on the pipe so that you can orient the new one correctly for a proper fit.
While the tank is out, it's a good idea to replace all the old rubber items, especially if you notice any cracks. Before installing the new tank, thoroughly clean it and remove any cosmoline or manufacturing debris using MEK (methyl-ethyl-ketone), acetone, or a similar solvent.
Additionally, ensure you have drained any remaining fuel from the tank before removal. Disconnect the clamps and remove the hose connecting the filler hole and the filler tube. You may also need to disconnect the fuel sender by unscrewing the brown ground wire from the top of the fuel tank compartment and detaching the other brown wire covered in a black plastic jacket.
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Clean the tank
Once the fuel tank has been removed, you can start the cleaning process. Drain the gas from the tank using a bulb-type siphon and mopping up any residue with old rags or paper towels. Next, inspect the tank for any debris and sludge, using a mirror and a flashlight to get a better view. Use a tool like a backscratcher to scrape away any debris or old sludge from around the tank. If there is a lot of dust and rust in the fuel tank compartment, use a screwdriver to remove it.
After the initial clean, you can decide how to clean the inside of the tank. Some people opt to take it to a radiator shop and have them "boil it out", leaving the inside and outside as bare metal. However, this will start to rust right away and will need to be repainted. If you want to do it yourself, you can use chemicals to clean the tank. One option is to use a restoration kit, such as the POR-15 kit, which includes a cleaner, metal prep, a sealer, and a fuel stabilizer. You can dilute the cleaner with water, but the weaker the solution, the longer it will take to work. Seal up all the tank openings with duct tape and use a tool to clear out the fuel hoses.
Another option is to use a different cleaner, such as Berryman's, and let it sit in the tank for a week. You can also use a toilet brush to scrub the inside of the tank and a pressure washer to rinse it out. If you are concerned about varnish buildup, you can use a paintbrush to apply the cleaner to those areas. It is important to note that the plastic components inside the factory tanks can dissolve over time and turn into a tar-like substance, so it is best to clean the tank properly to avoid further issues.
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Remove the ECU
To remove the ECU of a 68 VW Bus fuel tank, follow these steps:
First, remove the gas cap and take off the retainer ring. Inspect the filler neck as it may look okay, but you don't want it to crack after replacing the tank. The filler neck for 74-79 buses is available as a reproduction item from online VW parts vendors.
Next, remove the round black plate that covers the ECU. The ECU is located underneath this plate and can be removed to ease access to the filler pipe.
After removing the ECU, put the filler neck in from the outside and remove it along with the pipe. Take note of the position of the old filler neck on the pipe using a marker to ensure the new one is oriented correctly.
It is also recommended to replace all the old rubber items while the tank is out, especially if cracks are visible.
By following these steps, you will be able to safely remove the ECU of the 68 VW Bus fuel tank and complete the necessary maintenance or repairs.
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Engine removal
Step 1: Prepare the Workspace
Park your VW Bus on a flat surface and ensure you have all the necessary tools, such as spanners, sockets, and a floor jack. It is recommended to have a mix of spanner sizes (10mm, 13mm, 17mm, and 19mm) as different parts of the engine may require different sizes.
Step 2: Stabilize the Vehicle
If you are working on the roadside, consider parking another vehicle behind your VW Bus to reserve enough space and ensure your safety.
Step 3: Disconnect Wires and Hoses
Carefully disconnect any wires from the alternator or generator. If a wire has a "ring" connector between two nuts, use two spanners to avoid breaking the internal connection. Only disconnect wires that attach to the main loom. Clamp the rubber fuel line near the fuel pump, being careful not to clamp the fuel pump connector. Consider using genuine clamps or vice grips if necessary.
Step 4: Remove the Fuel Tank
This step may vary depending on your engine type. For fuel-injected engines, remove the return line. If you have a gasoline engine, remove the firewall between the fuel supply and the engine by unscrewing it from the top and bottom. Remove the tank vent lines and any brass/copper tubes. Drain the fuel tank and disconnect the fuel feed line.
Step 5: Address the Engine Support Bar
If your VW Bus has a bay window, it will have an engine support bar. Undo the engine support mounts on both ends of the bar, but you can keep the central part intact during engine removal. Place something under the gearbox to prevent it from dropping when the engine is pulled out.
Step 6: Remove the Engine
Use a jack to support the engine and remove the bottom two bolts first. Gradually remove the remaining bolts and carefully lift the engine out of the vehicle.
It is important to note that this process may vary slightly depending on the specific model and configuration of your 68 VW Bus. Always refer to a qualified mechanic or a detailed workshop manual for more specific instructions and safety precautions.
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Frequently asked questions
Here are the steps to remove the fuel tank from your 68 VW bus:
- Drain any fuel from the tank.
- Disconnect the two wires from the fuel sender on the top of the tank.
- Remove the breather lines on top.
- Undo the tank straps by unbolting them from underneath the body.
- Take out the fuel sender by twisting it counter-clockwise. You may need to tap it with a screwdriver and hammer to get it to rotate.
- Remove the tank.
Before reinstalling the fuel tank, clean away any dust and rust in the fuel tank compartment.
VW used 8mm OD hard fuel line from the tank to the filter and from the pump to the 3/4 fuel rail. You can use 5/16" copper tubing as a replacement.
Before installing a new fuel tank, it should be thoroughly cleaned. If the tank is coated in cosmoline, use MEK (methyl-ethyl-ketone), acetone, or a similar solvent to remove it.
