Been dreaming of a flangeless tank? It may be cheaper than you think.
Here is how I did mine.
Shopping list: (all prices are what I paid for my parts)
1. New Flangeless tank ($220.00) 05 and up C and F tanks are the same.
2. Walbro GSL393 fuel pump ($ 75.00 ebay)
3. Universal inline fuel pump kit P/N 400-939 (mine was included with my pump)
4. Banjo fitting 12mm P/N 128-3027 ($8.05)
5. I'm not sure what size fitting is included with the kit so buy this fitting. 8 mm hose fitting P/N 128-3024 ($4.22) (best fit for 5/16 hose.)
6. Banjo 12mm nut P/N N-011-069-1 buy it from your local VW dealer ($2.22) (Thanks to Jon's1800VTXC)
7. 6 feet of 5/16 fuel hose (low pressure is fine) ($7.00)
8. 6 feet of 3/8 fuel hose (low pressure is fine) ($7.00)
9. 1 of 5012K82 Acetal Quick-Disconnect Tube Coupling Socket for 1/4" Tube ID, 1/4" Coupler, Shut-Off Valve (McMaster Carr) (6.90)
10. 1 of 5012K83 Acetal Quick-Disconnect Tube Coupling Socket for 3/8" Tube ID, 1/4" Coupler, Shut-Off (McMaster Carr) (6.90)
11. 1 of 5012K712 Acetal Quick-Disconnect Tube Coupling Plug for 5/16" Tube ID, 1/4" Coupler, Shut-Off (McMaster Carr) (6.7
12. 1 of 5012K86 Acetal Quick-Disconnect Tube Coupling Plug for 3/8" Tube ID, 1/4" Coupler, Shut-Off (McMaster Carr) $6.78
13. 1 of 5012K72 Acetal Quick-Disconnect Tube Coupling Plug for 3/8" Tube ID, 1/4" Coupler, Straight Thru (McMaster Carr) $1.37 Each
14. 1 small universal fuel filter I got the smallest fram metal inline filter my auto store had. (5/16 hose)
15. Fuel sending unit. RESERVE UNIT 37810-MCH-F10 ($32.84) from HDL!
16. O-RING (39.5X5) 91305-MC7-000 ($2.50) from HDL!
17. NUT, FLANGE (6MM) 94050-06080 Need 4 ($2.50ea) from HDL!
18. If you have a C model you will need a new dash cover from honda and the bracket 17623-MCH-C10ZA 001 $86.66 F model dashes are a bolt on item except for the wiring.
If you have a retro I think all year dash units are the same.
19. 10 3/8 hose claps.
Total spent $397.56 and I'll add say 75 bucks for shipping and fudge factor so say $475.00
Now to off set that cost a little. Sell your old stuff.
I got $ 225.00 for my tank
$125.00 for my fuel pump
$ 25.00 for my dash cover
Make sure to keep your high pressure hose from your fuel tank and the fuel return line. We will use these!
For a total of $ 375.00 bucks back
My real out of pocket money spent $ 100.00 ! Still want to fill in that lip and repaint? Did I work for it YEP!
FYI: I traded my time to help a friend and he hooked me up with an F dash so this saved me BIG TIME.
Here is how to install:
Note: if you don't have your pair valve system removed and at least the back of your stock air cleaner box cut off install may be a problem.
1. Install the fuel pump above the throttle body as shown. You will want your high pressure fuel line routed before you mount your pump. I used self drilling/tapping screws.
Route the hose like this make sure to use the stock crush washers.
Rotate this clamp if it rubs on you hose.
2. Install a short piece of 5/16 hose between the pump inlet and the fuel filter (I had an extra fuel pump cover so I cut it to fit around my filter). Route the 5/16 fuel line from the filter under the back bone and into the left side of under the seat.
NOTE: I tried may spots to fit the fuel filter like under the back bone, by the intake, over the front cylinder, in the tool box, under the tool box behind the rear motor mount… I found where I put it to be the best spot to avoid having to loop a lot unneeded hose. If you can find a fuel filter that has one or even two 90* elbows on it you could put it a lot of other places.
3. Remove the fuel pump (brown) power wire from the black 3 pin connector. You can use a small pick to push the side prong over and it will release the pin from the socket. Now solder a new wire in (this is your 12+ pump power) (make sure NOT to cut the brown with a black stripe wire that one is for the sending unit!). Also make up a ground wire I connected it using one of the old mounting points for the pair system. The new fuel sending unit will plug right into the old socket. (Thanks again to Jon's1800VTXC for the great idea)
4. Set the tank in place. Plug in your vent line on the tank it is the smallest hose. I had to trim mine back some. Now you can figure out your fuel return line the new tank fitting is 5/16 so install the (Quick-Disconnect Tube Coupling Plug for 5/16" Tube ID, 1/4" Coupler, Shut-Off) on the hose and install the (Acetal Quick-Disconnect Tube Coupling Socket for 1/4" Tube ID, 1/4" Coupler, Shut-Off Valve) on your stock return line and connect the 2. The big 3/8 hose end under the center of the tank is a moisture drain from the top of the tank (I think this is only on the C and F tanks)
5. Connect a 3/8 fuel hose to the fuel outlet at the back of the tank. And route above the rear motor mount. Now loop the 5/16 hose around and back down as shown and use the quick couplers to connect the 2 hoses. FYI the extra 3/8 non shut-off fitting is for draining fuel from your tank!
5/16 hose looped
6. Tighten all you connections, install your fuel sending unit, install your dash, mount the tank, fuel and fire it up, check for leaks and go for a ride.
Sorry about the picture quality its hard to get good pictures with a flash...