The hose of death thread

My "hose of death" or "hose from hell" wasn't leaking yet, but I decided to go ahead and replace it while I had the intake and exhaust manifold off my van. Since I had everything on the left side of the engine removed, I figured I could do the job without cutting an access hole, but even then it was a bit hard to access. It looked manageable if I were to take the valve cover off, but I decided to bite the bullet and just cut the hole already. I mapped it out to fit the bend in my brake vacuum line that hugs the firewall there (I didn't want to move it nor did I want to damage it). The hole came out nice and it gave me plenty of access. I actually ordered the replacement hose from Toyota (Toyota Part # 15261-73030) but compared to Gates #28408 5/16" ID heater hose, it looked wimpy :?: . I decided to use the Gates hose. Surprisingly enough, the old hose wasn't leaking and actually was in pretty good shape. Taking into consideration it was 20 years old, I decided replacement was best. Here are some pics of the project.

1st step is getting the carpet and heater duct out of the way.
http://i8.photobucket.com/albums/a23...01IMG_8842.jpg


Next I laid out hole location and marked it with a sharpie. Ideally, I would have liked the hole to be another couple inches higher and to the left, but there's a steel vacuum line for the brake booster that is mounted there. Rather than mess with that, I compromised and decided here was the best.
http://i8.photobucket.com/albums/a23...02IMG_8843.jpg


Here is a Matco Air Saw. This thing is like a saws-all, but offers much better control for projects like this.
http://i8.photobucket.com/albums/a23...03IMG_8844.jpg


Here is the view through my newly cut access hole.
http://i8.photobucket.com/albums/a23...04IMG_8847.jpg


Here is how it looks from the engine side (note the steel vacuum line with the 90 deg bend).
http://i8.photobucket.com/albums/a23...05IMG_8848.jpg


Ample access for changing hose has now been granted. The upper end was a little more challenging, but still not bad. I used a 1/4" drive ratchet with a 1/4" socket to tighten the upper clamp. It was very manageable.
http://i8.photobucket.com/albums/a23...06IMG_8963.jpg


I used some .050 painted aluminum plate I had laying around and some 3/16" aluminum pop rivets to make provisions for re-installing the piece I cut.
http://i8.photobucket.com/albums/a23...07IMG_8851.jpg


I used some double back tape to stick the piece of insulation back on.
http://i8.photobucket.com/albums/a23...08IMG_8850.jpg


I used some 1/2" #6 self tapping sheet metal screws to secure the new access panel into place.
http://i8.photobucket.com/albums/a23...09IMG_8966.jpg


Okay, so you think that's the end of the tough little hoses to change? well guess what? There's another hose of death :doh:

The next hardest hose to conquer is another 8mm (5/16") hose that goes from the 19mm (3/4") steel heater hose return pipe up to an 8mm (5/16") pipe that attaches to the intake manifold. Although this one can also be a pain, it is not nearly as tough as the one I cut the access hole for. It can be done from underneath without too much trouble (at least on a 2wd, not sure about the 4wd). Here are some pics of it's location for your viewing pleasure :)>: . Tim
http://i8.photobucket.com/albums/a23...r/IMG_8784.jpg


http://i8.photobucket.com/albums/a23...r/IMG_8884.jpg


http://i8.photobucket.com/albums/a23...r/IMG_8780.jpg


Fully assembled view from under van:
http://i8.photobucket.com/albums/a23...r/IMG_8905.jpg


Gates hose is available by the foot at most auto parts stores. My local Napa usually carries it, but was out, so I went to Carquest and got some there.

Great thread! It sure helped me out...

I did another one of these last weekend. Pics are pretty self explanatory. Enjoy :)>:

http://i8.photobucket.com/albums/a23...m/IMG_0388.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0390.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0392.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0394.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0403.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0395.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0397.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0401.jpg

http://i8.photobucket.com/albums/a23...m/IMG_0387.jpg

Ah the love hate issue on cutting the walls ...


I think I'll try to convince my woman to use her tiny hands to help me out, har har har. :LOL2:

It can be done without cutting. When the valve cover is off it opens it up enough, but it's hard to see and easier to make a mistake. With the access hole it can be done easily and the metal pipe/nipple can be inspected. I consider the cut wall a non-issue as it's covered with a heat duct and carpet (no one will ever see it except maybe a mechanic). Tim

Yeah I would probably probably fab out a nice latch and hinge so no screws necessary.


Is the valve cover just a rubber gasket, if so sometimes I wouldn't mind taking the cover off to get at a hoke easier. (As long as you over it from debris :lol:)

The valve cover gasket is the rubber type that sits in a notch. As far as valve covers go, on the van it's somewhat of a PITA to remove (other junk in the way) but manageable. Changing the VC gasket is actually one of the things I'm doing on this van, but even so I still would rather have the access hole there. Hinge and latch would be nice I guess, but since that hose will last about 20 years I find the time and effort for that hard to justify. It doesn't take very long to remove 4 screws. Tim

Very true, have you ever thought of reinforcing the area you have cut before ?

I briefly considered it but due to design I couldn't see how a hole here (of this size) could have much effect on structural integrity.

I recently replaced a valve cover gasket on one of my rigs. It definitely took longer than expected. If you go that route plan on replacing the (3) valve cover grommets and possibly the PCV grommet as well. I found them all to be brittle, sections broken off, etc.

Very true ...

Looks solid and it won't make any more noise.

I got a big surprise yesterday when I pulled away from my house and noticed a big oil stain on the ground (bigger than usual I guess). So I parked in the garage this morning so I could see if it was me. Another 2-5 oz's of oil leaked out on my cardboard oil catcher. As best as I can tell right now it is coming from a weep hole at the front of the housing. I went through my chiltons manual but its worthless. Any thoughts? Also, I have a slow leak at the back of the transmission pan. I changed the pan gasket but it continues.... Is there a seal just above the rear of the tranny pan? Thanks for any input. Cirrus
In the photo its the small hole on the only clean area.
Attachment 847

It could be coming from your rear main engine seal or from the transmission input shaft seal. If it's red and thin, then it's the transmission. If it's thicker and brown/dark brown, then it's probably the rear main engine seal. If you can't tell, take out your dipsticks and put a drop of oil on the cardboard next to the drip that's there. The one that matches the best will be the culprit. Either way, the transmission or engine has to come out in order to repair. The other option is to carry around extra oil/transmission fluid and top off regularly :dizzy:. Tim

Thanks for the reply Tim. Spent some time looking when I got to work. It's engine oil, coming from up high, runs down the left side of the bell housing where the tranny meets the back of the engine. Kinda through me for a loop cause all my fluid levels are good and this is new leak. oil spot on the ground is 1 foot by 4. Crankcase has gas smell but oil may need a change. I am trying to get it into the shop to have them look at it. Hoping I didn't buy a basket case!
one last thing, it seems to leak right after I shut the engine down for maybe 5 minutes

I have another update...... I think it's coolant. Because it was golden in color I automatically thought it was oil. Radiator light came on so I smelled the drip and it smells like coolant. I thought it was supposed to be red. Anyway, it's coming from the top rear, maybe head gasket? Are there any coolant hoses back there? I can't see any. Thanks!

Ok I think I have it located..... Small pipe (1/4- 3/8) coming from above left side and crossing the back. Where it goes through a bushing looks like its worn through and leaking. Hard to see in the pic ( in between the 2 bolts). I imagine its a bear to get to?
Edit: Brake Line?

Attachment 849

It's a little hard to get orientation from that picture, but it sounds like/looks like the bypass hose AKA "the hose of death". Here's a picture of the back of an engine.........the hose of death is the one coming from the plate on the back of the head.

http://i8.photobucket.com/albums/a23...ps1f55cfbb.jpg

Hi Tim, first, thanks for all you do in answering questions, running the site, etc! It's actually the hose just below the hod, the small one, its leaking at the rubber bushing that it runs through. What is it? Van's in the shop right now, the owner didn't get all the info I gave at the check in and did not look specifically at this hose so he was going to look tonight.what he did was do a general evaluation and here's what he recommends I take care of in the future.Seal just above the back of the transmission pan.transfer case sealredo front wheel bearingsreplace motor mountshe is suspicious of the head gasket because he see's some signs of burnt radiator fluid there, and that's the one I am worried about. All the rest seem like they shouldn't be that big of a deal?Thanks again,
Cirrus
Another observation, the fluid smells like old tire air

If you're talking about the steel line that runs under that plate, that's the fuel return line coming out of the fuel pressure regulator. If that's leaking then it would be gas (not antifreeze). IMO that's not too likely (as it's steel and it's tough). What's more likely is the hose above it (the hose of death) dripping coolant down onto it, making it appear to be leaking. Tim

Ok Tim, thanks, I will call the shop this morning and have then check it.
Cirrus

getting ready to do it myself. More pics to follow.

Attachment 854