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 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. 3. Loosen Clamps that connect the gas tank to the filler neck 4. Disconnect the vacuum hose. 5. Lift gas tank out and into trunk area (get a buddy to help you) 6. Remove breather hoses and filler neck hose (not pictured) from tank 7. Loosen cap on gas sending unit 8. Remove gas sending unit 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. 10. Connect new filler neck hose and clamps to new tank 11. Connect new vacuum hose 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.) 13. Secure the sending unit in place 14. Sending unit cap brackets should run up & down 15. Install a new gas line hose 16. Install new breather hoses and attach to new gas tank 17. Hook new gas line to gas tank 18. Slide new clamps onto filler neck hose. You won't be able to get them on when the tank is installed 19. Lift & position tank in place 20. Tighten clamps on filler hose. If they are not tight after installation, gas will leak through and onto your trunk compartment 21. Reattach vacuum hose 22. Reattach sending unit wires (colored wire head goes on the passenger side bracket) 23. Add retaining clamps and tighten 24. After new tank and installation