How do I drain a gas tank with a dead pump

[zubaroo]

94 gs fwd v6. My fuel pump appears to have died suddenly on a full tank of gas. I really don't want to remove the tank while it is full. Seems the easiest (only?) way to drain the tank is to use the fuel pump but this is not an option for me.

The Haynes says to siphon before removal, but no details about how. I tried siphoning with various sized hoses - seems they won't go around the S bend in the filler hose.

I disconnected the feed and return lines and pressurized the tank (with my air compressor and a home made adapter to make a tight seal over the gas cap opening) to push the gas out the feed line - nothing.

I'm about to disconnect the filler and vent hoses to siphon from there but expect a flood of gas when they come off. Anyone have experience and advice for this situation?

[rhandwor]

Usually the gas will run out if the filter is disconnected. I've used an air nozzle and some rags and removed fuel gas in a diesel fuel tank. I would be afraid of popping a gas tank using a setup like you did. Surely the return line or the suction will let gas out.
I always used a jack and dropped the tank full but I understand not wanting to do it because it requires help to steady the tank.

[zubaroo]

The send and return lines seem to have pressure valves (to prevent an engine fire from entering the tank?) Even with these disconnected, no air or gas would come out when I pressurized the tank. The pressure I used was probably not much more than typically builds up in the tank on a hot day.

I haven't disconnected the EVAP valve line yet but it is too small to siphon through and enters near the top of the tank so it would not drain from there.

Looks like I may have to put wood blocks between the tank and the ground, take off the straps and jack up the van.

Should I expect a flood of gas when I disconnect the filler hose on a full tank?

[rhandwor]

It depends on how full the tank is at this time. Loosen the clamps and then loosen the hose if gas is that high it will start leaking have a five gallon bucket at this location ready to collect any gas. You will need a long piece of wood
and somebody to steady the tank when you let down the floor jack. I use a piece of plank about 2 foot long on the tank and a floor jack under it.

[zubaroo]

I'm running again! I'll post my experience for the benefit of others.

Went to an auto wrecker and pulled a gas tank off another 94 Villager for practice and to have a good look at all connectors for siphoning options. It was several hours and a lot of effort with stubborn bolts, but useful experience.

Back on my van, I had already disconnected the negative battery terminal, tank electrical connection and all small hoses and jacked up and removed the rear driver’s side wheel. I now disconnected the filler hose at the body end but still could not snake a siphon hose through the S curve in it. Disconnected the other end, tank side, and with my finger could feel a rubber flap, hinged at the top, that prevents gas from gushing out. Got a siphon started from there and collected about 50 litres, leaving about 2 litres. Put a 2 foot long 2x6 across the back of the tank and supported it with a hydraulic jack. Removed the back two bolts for the straps. Slowly released jack pressure to lower the tank. Checked the weight of the tank by hand and it was light enough to pull the board and jack out and lower by hand to rest one end on the ground.

In that position I replaced the fuel pump but had difficulty with both the rubber gasket not seating and the sending unit float catching on the bottom of the tank while trying to reinstall it in that position. Don't do this!

I removed the back cotter pins and supported the front of the tank by hand while pulling the strap pins. Slid the tank out from under the van. This was much easier to work with than working under the car cramped over the back axel. I siphoned the remaining gas which allowed me to also get the dirt and debris out. The gasket would not seat properly in the groove. Put a little axel grease on it and that worked great.

Reinstallation did not present any notable challenges. The hoses that were hard to get all the way back on I sprayed with silicon spray. Before putting the mud guard and back wheel back on, I put a 25 litre jug of gas in the tank and checked for leaks. Then I turned the key on and could here the fuel pump pressurize the line. Checked for leaks again and then cranked the engine. Started right up. Whoohoo! Mud guard and wheel back on, removed jacks and wheel blocks and filled the tank.
In terms of cost, the pump was $288 at Canadian Tire, $395 at Lordco and $95 used at auto wreckers. I wanted new but not original manufacturer since these pumps have been problematic for Villager/Quest owners. I opted for $30 on eBay and $40 for express shipping for a new pump with warranty. Took a week to arrive due to the border crossing but I had a borrowed car so could afford the wait. The pump didn't come with a strainer so got one from Lordco $10 and figured I might as well do the fuel filter as well, $17 at Canadian Tire. I'm sure I saved several hundred dollars in shop labour.

One last piece of advice: pay close attention to the orientation of the strainer on the fuel pump before replacing or when putting a new one on a new pump. When mounted on the pump, the strainer on my tank extended directly towards the back of the tank and sat in a shallow canal.

The repair would have been easier if the tank hadn't been full when the pump died. Nevertheless, for $100 in parts and a day or so of labour, my steed is mobile once again. Now I can move on to the axel noise, dead cruise control, low heater output, side door latch, flaking paint, back shocks...