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Beetle Gas Tank Removal and Installation

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VW Gas Tank Replacement

VW Gas Tank Replacement

Most Air Cooled VWs have seen their share adventures, some that have left the gas tank dented, damaged or leaky. Replacing a Volkswagen Gas Tank is a task that can be done by an average mechanic as a weekend project. Mid America Motorworks takes you through the steps for replacing a 1972 Super Beetle Gas Tank.

Getting Started

Any task is made easier with the right tools. Here's what you'll need for this project:

  • Regular Screwdriver
  • Ratchet with Extension & 10-14mm Socket
  • Hammer & Wooden Chalk
  • Friend to assist with removing the tank.
  • New Gas Line, Filler Neck Hose, Gas Sending Unit Seal, Breather Hoses
  • New Clamps
tools you need

Gas Tank Removal

Begin the project by disconnecting the battery of your VW Beetle. Then, siphon out the gas, leaving the tank less than a quarter full.

Using a screwdriver, remove the retaining clips from 4 points on the gas tank. Next you'll want to loosen the clamps that connect the gas tank to the filler neck hose. Disconnect the vacuum hose from the gas tank.

Now you're ready to remove the gas tank. With assistance, lift the tank out and into the trunk area.

Remove the breather hoses and filler neck hose from the gas tank.

Using the hammer and wooden chalk to create leverage, loosen the cap on the gas sending unit. Once it is loosened, you'll want to remove the gas sending unit by rotating the cap to one side and then lifting the unit up and out of the tank.

Remove the gas line hose located at the bottom of the tank and you're ready to remove the tank completely from your Super Beetle.

disconnecting the battery siphoning the gas and removing the retainer clips
loosening clamps
3. Loosen Clamps that connect the gas tank to the filler neck
disconnecting the vacuum hose
4. Disconnect the vacuum hose.
lifting the gas tank
5. Lift gas tank out and into trunk area (get a buddy to help you)
removing breather hose
6. Remove breather hoses and filler neck hose (not pictured) from tank
loosening cap on gas sending unit with a hammer and block of wood
7. Loosen cap on gas sending unit
removing gas sending unit
8. Remove gas sending unit
removing gas line hose
9. Remove gas line hose

Gas Tank Installation

Place the new gas tank into the trunk of your Volkswagen. Connect the new filler neck hose and clamps to the tank, then connect the vacuum hose.

Add a new seal to the gas sending unit before re-installing the gas sending unit. When placing the sending unit into the tank, be sure to feed the sending unit in straight down from the opening for the correct angle. Using the hammer and chalk, secure the sending unit cap back in place. The gas sending unit cap brackets should run up and down with the tank.

Once the sending unit is in place, install the new gas line and breather hoses. Then attach them to the new gas tank. Next, hook the new gas line to the tank. Slide the clamps onto the filler neck hose now. You won't be able to reach them when the tank is installed.

Lift and position the gas tank in place. Tighten the clamps on the filler hose. If they are not tight after installation, gas will leak through onto your trunk compartment.

Reattach the vacuum hose and sending unit wires. The colored wirehead goes on the passenger side bracket. Add retaining clamps and tighten them in place.

Once the gas tank is installed, reconnect the battery and refill the tank with gas. Confirm that all hoses and clamps are securely in place. Start the Super Beetle and check that the gas gauge is working properly. Be sure to let the gas run through the VW for a while before driving.

new gas tank with required hoses and clamps
connecting new filler neck hose
10. Connect new filler neck hose and clamps to new tank
connecting new vacuum hose
11. Connect new vacuum hose
adding the seal to the gas sending unit
12. Add a new seal to the gas sending unit (When placing the sending unit into the tank, be sure to feed the sending unit in straight down from the opening for the correct angle.)
securing the sending unit in place
13. Secure the sending unit in place
showing the proper position of unit cap brackets
14. Sending unit cap brackets should run up & down
installing a new gas line hose
15. Install a new gas line hose
installing new breather hoses
16. Install new breather hoses and attach to new gas tank
hooking new gas line to gas tank
17. Hook new gas line to gas tank
placing new clamps onto the filler neck hose
18. Slide new clamps onto filler neck hose. You won't be able to get them on when the tank is installed
lifting & positioning tank in place
19. Lift & position tank in place
tightening clamps on filler hose
20. Tighten clamps on filler hose. If they are not tight after installation, gas will leak through and onto your trunk compartment
reattaching vacuum hose
21. Reattach vacuum hose
reattaching sending unit wires
22. Reattach sending unit wires (colored wire head goes on the passenger side bracket)
adding retaining clamps
23. Add retaining clamps and tighten
the new gas tank installed
24. After new tank and installation