Vanagon Fuel Tank Re-Seal: Part 1

One of the first major things I noticed when I got the van was the smell of fuel whenever I filled the tank. I would later learn, as almost every new Vanagon owner does, that this means the fuel tank vapor control system would need to be re-sealed, which consists of replacing some grommets, a crossover pipe, and a few section of fuel hose. This also requires dropping the fuel tank and an extra set of hands (or some intricate jack work). Which leads me to one of my main problems - we live in an apartment and don't have a dedicated parking spot nor a garage or car port. So, this makes it very hard to do bigger jobs as that would mean I would need to do it on the street. The job still remains half done. (Dumb, I know, I just haven't found the space/helper to finish the job.)

You can see the hoses coming off of the expansion tank just getting soaked after filling up.

You can see the hoses coming off of the expansion tank just getting soaked after filling up.

Whoa! Needless to say, I was suuuper freaked out after seeing this. But, just like anything in life, after educating myself on the problem, I was able to approach it with confidence.

Whoa! Needless to say, I was suuuper freaked out after seeing this. But, just like anything in life, after educating myself on the problem, I was able to approach it with confidence.

Note: It's worth it to go with a kit rather than trying to piece everything together. In the end, I spent a lot of time going back and forth (because shop guy didn't give me enough clamps or hose, etc) and the time, combined with with the fuel, and just the cost of everything turned out to be way more than just getting a kit. I would recommend the Fuel Tank Re-Seal Kit from GoWesty. Also, check out the diagrams mixed in with the product description pictures; they give you a better view of what's going on under there.

Yup, that's a big F'n hole.

Yup, that's a big F'n hole.

There are two short runs of fuel lines coming off of the expansion tanks on both the driver and passenger side of the van. These lead to hard lines then two more (per side) short runs of fuel lines that attach to the tank and the crossover pipe. The two fuel lines (per side) that come off the expansion tank are accessible from outside the van at each wheel well. The others...that's where dropping the tank comes in to play and that's what I still have yet to do.

Here's a shot of the new fuel lines coming off of the passenger side expansion tank.

Here's a shot of the new fuel lines coming off of the passenger side expansion tank.

The GoWesty kit calls for a special tool, pincer pliers, to put their ear-style hose clamps on. I'm not sure if I had the same style of clamp, but I used some old side cutters and they worked fine. But, if you have the cash, maybe just get the special pliers?

Anyway, I'll update this post when I finally complete the job. I'm anxious to see what improvements (if any) this will have on my MPG.