Sometimes you think you’re badass. And then something bad happens and you’re just an ass.
Worked on the van: Drain coolant, replace thermostat, remove coolant tank and expansion tank (Vanagons have a radiator, a tank, and an expansion tank), clean the tanks all nice and shiny (20 years of nastiness in there…), pull the distribution unit (big plastic junction, requiring removal of four hoses) so I could get to the hose that goes to the radiator. Because it’s been leaking in drips and drabs.
Now, at this point, everything’s apart. This is the perfect opportunity to replace the last remaining bit of fuel line. I’ve been wanting to get this done for quite a while, just to finish out my complete re-do of the fuel system. And the only reason it hadn’t been done is because it’s such an awkward place to get to unless everything beneath it is pulled. So I decided to do it, even though I had a bad feeling about it.
It’s a two-inch-long piece of rubber hose connecting a plastic nipple on the firewall to another plastic hose that runs up from the fuel pump and filter. Two inches! I wrestle with the little nipple fitting thingie, which is there purely to make it easier for VW to manufacture the vehicle, and I wrestle with the hose clamp, and then I wrestle with the other hose clamp, which I have to cut with mean-looking cutters.
So far so good. Cut some new hose to length, put on the fancy new gentle-on-hose clamps, put it all back together, good to go.
Reassemble everything, pour in some coolant, pour in some water (distilled water from the grocery store)… The moment of truth!
Turn the ignition on without starting the engine. Hear the fuel pump whir. Look under the van for leaks… None. Start the engine, look for leaks… None.
Start pouring in more water and coolant as it’s drawn down. This is how you’re supposed to do it, by the way. Hum-de-dum. Check for leaks… None.
Wait, what was that? Turn off engine. It’s a puddle of gas. A big one. This is exactly the leak I was trying to prevent by replacing the 20-year-old hose!
It turns out I crushed the plastic hose by overtightening the clamp. The fix is to cut the plastic hose short and put on a new piece of hose, or just replace it with a full run of rubber hose. But now it’s night, and it’ll wait until tomorrow.
I’m an ass, though, because I made a huge gas stink throughout the house. Landlady not happy.

