1961-1967 Beetle and Ghia Fuel Tank

The first step to restoring smooth reliable operation to your VW is replacing the rusted fuel tank and lines. Loose dirt, debris and rust scale in your Volkswagen's fuel system rapidly clog fuel filters and plug carburetor jets, leading to poor idle quality, decreased performance and reduced fuel economy.

Make your installation fast and trouble-free with our fuel tank installation kit assembled specifically for this fuel tank. See The You Will Need Tab Above.

One Fuel Outlet and Threaded Plug

Corrosion-inhibiting Coated Interior

Fabricated from High-Quality Steel

Seam Welded and Pressure Tested

Our Gas Tanks for 1961-1967 VWs are made to OEM VW specifications. Each tank is painted black and is a direct fit to your Beetle or Ghia.

Important Tech Note !

All fuel tanks are manufactured with a sprayed-on interior rust inhibitor. This lining must be removed prior to the installation of your new tank. Failure to do so could cause your carburetor or fuel injection to clog up when gasoline dissolves the preservative and it passes into your vehicle’s fuel system.

Here is the method we employ to prep a fuel tank prior to installation:

•   Close off tank openings with rags and duct tape
•   Add a cleaner such as Carburetor Cleaner, Acetone, or MEK (Methyl Ethyl Ketone)
•   Caution – No Smoking or Open Flames nearby.
•   Add some small metal parts such as nuts, bolts or washers, then shake and rotate tank. This causes the preservative to break down and dissolve.
•   Pour out and repeat until the cleaner drains out clear. Dispose of the used cleaner properly.
•   Remove rags, tape and metal parts. Allow tank to dry and your tank is ready for installation.

VW Gas Tank Replacement

Name: VW 1961-1967 Beetle and Ghia Fuel Tank
SKU: 336-025
Price: 194.99 USD
Availability: InStock

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

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.

loosening clamps — 3. Loosen Clamps that connect the gas tank to the filler neck

disconnecting the vacuum hose — 4. Disconnect the vacuum hose.

loosening cap on gas sending unit with a hammer and block of wood — 7. Loosen cap on gas sending unit

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.