1965 Volkswagen Type-1 (Beetle) D.I.Y. Project (o\_!_/o)

[nmshaikh]

Fire Extinguisher is on this time Islamabad visit buying list. I have all the details already worked out on its availability & pricing.

About the possibility of a customized seal rubber crumbling into the tank and finding its way to the fuel line, I had this in consideration and would be fitting an aftermarket filter between the tank tap and the fuel line (below tank) for now until the Israeli/Indian filters requested arrive.

About the rubber boot on top of the sending unit, will keep you posted once I have unmounted the sending unit and would see if the complete sending unit needs replacement or would it do for now. Nonetheless, will look for a replacement used sending unit to have in stash for any future worse case scenario.

I would suggest not removing the sending unit from the tank before you check if the source of leakage is the top of the unit. It may be that the seal between the sending unit and the tank is holding good. Once you open it up, the seal would need to be replaced anyway.

[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[nmshaikh]

Sunday started early today with lots on the list to accomplish. The foremost was the Leaking Sending Unit on the Tank.

Took the suggested route and removed the metal cover to find the top goblet filled with leaking fuel.

Was disappointed but not for long. Cleaned and dried the area and the problem was sorted out. Its the leaking seal and not the goblet on the top!

Here are the pictures:

Look at the following picture that highlights the area where from the seal is mostly worn out and the fuel is seeping out. As soon as the area was dried, this was the area which immediately got wet with leaking fuel after drying.

Comments/advice before I could head further to remove the sending unit for replacement of the seal?

Try tightening the three screws and see if that helps...and why stop at three? Go ahead and tighten all five and see if that helps. If all else fails, let me know and I'll send you the proper gasket.

DO NOT use silicone sealant. see if you can find a thin cork sheet and try cutting a gasket. Your problem, if the fuel has started to leak from under the sending unit, is the failed seal and the two surfaces should be pretty much level. For sealing, you need a material that does not react to fuel and presses as the screws are tightened.

[reezvaan]

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[reezvaan]

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[nmshaikh]

Leakage has reduced exponentially from the seal but still its leaking. It would need replacement.

I can even see the goblet now leaking a little too.

@nmshaikh Please send an original piece whenever possible. Until such time I will sort a cork sheet out and would cut a seal out of that for now.

Please choose a THIN cork sheet (the thinnest available). When you tighten on a thick sheet, the screws when tightened would bend the area slightly leaving the area between two screws slightly raised thus allowing more leakage.

I'll see if I can pick up a gasket locally and send over this once. Until you get this sorted, please do not fill up more than three quarters of the tank. (and get used to the smell of gasoline)

[reezvaan]

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[muj_talpur]

Hey reezwan brother. My fuel guage is the same as yours. It neva works even if i fill the tank to top. When i bought the car the sending unit was out of order. I got it replaced with a new one but still my sending unit is sending nothing :(. Can you please advice me on how to get it in working order. The bottle thing in the end is no damaged because i check it or else it would had petrol deposits in it. and when i manually drive the sending shaft. It works I could feel the movement. Secondly my tank has got a lot of rust in it. How can i clean it up and make it rust less. My car stops sometimes though it has plenty of petrol residing in the tank.