Before you begin:
* Safety First: Disconnect the negative battery terminal to prevent accidental sparks near fuel. Work in a well-ventilated area, away from open flames.
* Gather Tools: You'll likely need various wrenches (possibly sockets and ratchets), screwdrivers (Phillips and flathead), pliers, a fuel line disconnect tool (highly recommended), safety glasses, and gloves. A shop rag or absorbent material is crucial for cleanup.
* Obtain the correct replacement hose: Get the exact replacement gas filler hose for your year, make, and model. Auto parts stores can help with this, providing the correct length and fittings.
Steps (General Outline - Consult your repair manual for specifics):
1. Access the Fuel Filler Hose: This usually involves removing some panels or trim pieces under the vehicle, near the fuel tank. Your repair manual will show exactly where. Expect some potential rust or difficult-to-remove fasteners.
2. Disconnect the Old Hose: This is the trickiest part. The hose connects to the fuel tank and the filler neck. There are likely clamps securing the hose to both connections. You'll need to:
* Loosen the clamps: Use the appropriate pliers or a clamp removal tool.
* Disconnect the hose: This might be a simple pull, but be prepared for resistance. A fuel line disconnect tool is invaluable here to help avoid damaging the hose connections. If the hose is brittle, it could break easily.
* Carefully support the fuel tank: As you work, be mindful of the weight of the tank. You may need to use a jack or support straps to prevent it from dropping unexpectedly.
3. Remove the Old Hose: Once disconnected, remove the old hose from its routing. Note how it was routed – you’ll need to replicate this during reinstallation. Take pictures if necessary.
4. Install the New Hose: Carefully install the new hose, following the path of the old one. Ensure it's correctly positioned and seated.
5. Connect the New Hose: Attach the new hose to both the fuel tank and the filler neck. Secure with clamps. Ensure the clamps are tight enough to prevent leaks but not overtightened, potentially crushing the hose.
6. Reconnect and Test: Reconnect the negative battery terminal. Carefully check for any leaks around the hose connections. Fill the tank with a small amount of fuel and check for leaks again.
7. Reassemble: Put all the panels and trim back in place.
Important Considerations:
* Fuel Spillage: Expect some fuel spillage when disconnecting the old hose. Have absorbent material ready.
* Hose Routing: Pay close attention to the routing of the hose. A kinked or improperly routed hose can restrict fuel flow or cause damage.
* Clamp Tightness: Improperly tightened clamps can lead to leaks. Use the correct amount of torque.
* Fuel System Pressure: The fuel system may have some residual pressure. Relieving this pressure before disconnecting the hose is a good safety practice; consult your repair manual.
This is a general guide. Always refer to your vehicle's repair manual for specific instructions, torque specifications, and safety precautions. If you're not comfortable performing this repair yourself, take your van to a qualified mechanic. Working with fuel systems requires caution and expertise.
