Eurovan Camper mods

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Eurovan VW T4 - Drop the Fuel Tank

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Created 2025-09-22 Work in progress

Notes on dropping the fuel tank in a 2000 Eurovan (VW T4).

Tools

Step-by-Step:

(click each picture for full size)


  1. Jack up the van or drive the front end up on ramps.
    I used ramps which gave the front tires about 6" of lift, which puts the side rail about 15" off the ground. This was barely adequate, as the fuel tank filler neck sits about 23" off the ground. If possible, lift the van so the left side rail is 20" off the ground.

  2. Make sure there is only a gallon or two of fuel in the tank.
    Siphon extra out if needed.
  3. Disconnect negative ground to starter battery
  4. Remove rear heater vent.
    Two #1 Phillips screws near the top.
  5. Remove left captains chair
    Four 16 mm head bolts and one electrical connector
    Removing the right chair is optional, but doing so gives you more room to work, and only takes a few minutes.




  6. Remove hand brake shroud
    Two plastic pieces which simply pop off.
  7. Remove driver side seatbelt (lower bolt, 17mm socket).
    Remove the Phillips screw on upper part of trim.
    This loosens the trim so you can reach the edge of the carpet underneath
  8. Peel up carpeting starting at far left rear.
    You do not need to remove it fully. This picture shows how far I pulled it up to reveal the fuel pump cover.
  9. Remove parking brake mechanism.
    Three 13 mm nuts
    Move the mechanism slightly to the side to give room to access the fuel pump cover. You do not need to disconnect the parking brake linkage. Note: remember to put chocks behind the wheels if the parking brake is off.
  10. Remove the fuel pump cover
    Three #2 Phillips screws
  11. Vacuum area around fuel pump, look for cracks or leaks.
  12. Remove fuel line spring clamps - the left one is likely under pressure so have a rag handy to catch the gasoline
    • Clamp fuel lines around drill bits or small sockets after removal to keep from leaking.
    • (not shown) put a short piece of tubing to connect the pump inlet and outlet -- this keeps dirt out, keeps gas fumes in the tank, and will be needed later if you decide to pressure test.
    • Remove the electrical connector.

  13. Back on the outside of the van, remove gasket around gas cap.
    There is a metal C-shaped metal 'tensioning ring' which holds it into place.
  14. Remove 10mm bolt near gas cap
  15. Back under the van, support the fuel tank with a jack
  16. Loosen fuel tank straps, 13mm socket.
    There are 5 bolts: 3 at the rear, and 2 at the front.
  17. Remove straps, lower fuel tank a couple inches then stop.
    Look for anything hanging up tank before lowering all the way - on the front of the tank some of the evap hoses may be clipped in and you need to pop them free.
  18. Lower the tank completely.
    Sliding the fuel tank out from under the van was difficult as I only had the left rail about 15" from the ground. I removed the gas cap which gave me a little more clearance and I was able to wiggle it out.
  19. Success!


Things to do with the fuel tank dropped