Replace fuel lines includes the lines from the gas tank, lines in the engine compartment, the return line to the gas tank and especially the small lines between the fuel rails and fuel injectors. The rubber fuel lines get corroded by ethanol in gasoline and should be replaced approximately every 3 years. If you don’t know when the lines were replaced just do it. It took Corey a few hours.
- Vanagons use specific 7 mm high pressure rubber fuel lines and plastic fuel lines around the rear wheel wells. (Buying the wrong fuel lines can lead to ballooning of lines and fires)
- Remove the plastic grommet/nipple piece in fire wall. This piece is known to fail spraying gas all over your engine compartment. It is located behind the airflow meter on the right back wall of the engine compartment. (You will put a rubber grommet in the opening and just run the fuel line through the hole)
- After researching, and even before our partnership with GoWesty, I found their Fuel Line Replacement Kit to be the best. GoWesty also offers the Hard Plastic Fuel Line Replacement Kits for around the wheel wells. If you really want to go the distance you can replace the old plastic fuel rails with with the new Aluminum Fuel Rails.
- Its also a good idea to replace the fuel pump (keep the used one as a spare) and filter when you do the lines. Both are found in line on the passenger side, just go under the van below the sliding door and you should see two silver cylinders. We recommend buying Bosch products when you can. GoWesty has both. Fuel Pump and Fuel Filter (for late model Vanagon 85-91) Fuel Filter (older model Vanagon80-85).
- Replace the non-pressurized 12mm fuel line (from the fuel tank), fuel pump and filter first and all at once. (Pre-assemble this section)
- There will be another section of rubber fuel line from the fuel filter to the plastic line. (Measure twice or three times then cut)
- Here are easy to follow Instructions for replacing the fuel lines in the engine compartment.
- Replace the small section of rubber hose on the return that attaches to the gas tank.