Date: Thu, 25 Jul 2002 20:54:07 -0400
Reply-To: George Averill <averill@LDL.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: George Averill <averill@LDL.NET>
Subject: Replacing Gas Tank Cross-Over Pipe on 84 Vanagon - Without
Removing the Gas Tank!
Content-Type: text/plain; charset="iso-8859-1"
It can be done! I just did it!
Procedure:
1. Have parents with genes for small, strong hands!
2. Find a friend with similar genetic heritage.
3. Remove spare tire.
4. Remove cover for spare tire. (allows more room for small hands)
5. Jack up front of vehicle and set each side on a jack stand.
6. Remove both tires. (allows more room for small hands) (Hint: Loosen lug nuts before jacking up!)
6. Find the cross-over pipe by looking through the center of the spare tire compartment. You may want to use a mirror and a good light to see exactly where things are located.
7. Follow the two small rubber lines (one on each side of the cross-over pipe) to the expansion tanks located on either side.
8. Disconnect the fittings to the rubber line at the expansion tanks. (You can reach these, but not where the lines attach to the crossover pipe.)
9. Use hands and/or small pry bar to pop out the plastic fittings on the cross-over pipe that go into the tank. (Best done from the sides through wheel wells.) They should come out without too much pulling.
10. Withdraw cross-over pipe with remaining short hoses attached. ( Have your fried pull from the left side of the vehicle while you feed things over and around the various pipes.
11. Remove the hoses which are attached to the old cross-over pipe and reattach them to the new cross-over pipe.
12. Lubricate the two rubber grommets in the tank and the plastic fittings on the cross-over pipe that get inserted into them. I used silicone lube.
13. Have friend slide cross-over pipe through from left side wheel well of vehicle while you (located inside the spare tire well) feed the hoses over the other various hoses and pipes until it is in place on both sides. Your goal is to make the cross-over pipe fit neatly without having to be bent. Bending will work for a while, but eventually results in a fitting breaking at the tank.
14. Press the fittings into the tank.
15. Loosen the Phillips screw in the hanging bracket in the center of the under side of the van just enough to fit it over the cross-over pipe. Retighten. (I used a small, flat, ratchet-type Phillips screwdriver.)
16. Reconnect small hoses to expansion tanks, replace tires, spare tire cover, spare tire.
Voila! You did it! Now the gas won't run out when you fill up the tank or go around a curve!
OPTIONAL STEP FOR THOSE OVER 60!
17. Take a short nap after finishing while still under the van, get up and take more pain medicine (your choice), eat supper, forget about partying, and go to bed early!
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