[Justin Kerns]

I just did this fix myself today. I had a strong gas smell inside and outside the van regardless of full tank, empty tank whatever. No evidence of leaky fuel pump but I could shine a flashlight on the pressure regulator and see that it was dry before starting the van and then as soon as I started it I could see gas around it. Replaced the o-ring per the above instructions and so far it looks dry. I drive 50 miles each way to work every day so I'll find out soon enough if that was my only fuel leak problem!

Thanks for the clear instructions. O'Reilly is my closest store and they had a Dorman variety pack of vitron o-rings (safe for fuel exposure) that cost around $8. There was one in there that was the right size.

Justin

 

[Justin Kerns]

Well my fix did not hold. It has started to leak again and seems to be getting worse. I'm going to have to bite the bullet the replace the whole rail. Oh well you win some you lose some!

Looks like $70-$80 for the part depending on where you get it.

Justin

 

[Justin Kerns]

It is leaking from the "pulse damper" like it was before. It held tight for almost 2 months but then I smelled gas again and sure enough it's the same thing. It's worsening at a much faster pace than before. I've ordered a new rail assembly and will have it Monday or Tuesday.

I do drive my van a lot - over 100 miles a day for work so from a mileage standpoint it lasted a while. But it definitely isn't a real fix for me anyway. I was careful when bending the prongs back into place and making sure the cap gripped the pipe securely. Maybe it isn't a serviceable part or maybe the o-ring I used was slightly too small or something. It's hard to diagnose it exactly. YMMV.

 

[Justin Kerns]

I was pretty careful when I re-assembled mine. I bent the tangs just so and it held tight after I put if back on. I couldn't remove it without tools. I don't know why some leak again and some don't. Maybe mine has another problem like a hairline crack or something.

In any event I think it's worth trying to replace the o-ring because it is relatively easy, cheap and fast. It seems to work for some people but not all.

Justin