Post by sall on Oct 2, 2012 17:19:53 GMT -6
Fuel Line Replacement: Nylon Line Between Fuel Rail & Steel Lines Near Firewall:
Particularly I am replacing the Fuel Feed Line which is the larger 3/8" diameter line. The other line at the fuel rail is the Fuel Return Line. The Return Line is 5/16" in diameter. Both lines can be replaced in similar fashion by using the correct size Quick-Connect fitting and nylon fuel line.
Parts Required:
Fuel Feed Line(3/8"):
Dorman 800-082 - Fuel Line Quick Connector Adapts 3/8 Inch Steel to 3/8 Inch Nylon Tubing
Dorman 800-075 - Nylon Fuel Line 3/8 Inch x 10 Ft
Fuel Return Line(5/16"):
Dorman 800-080 - Fuel Line Quick Connector Adapts 5/16 Inch Steel to 5/16 Inch Nylon Tubing
Dorman 800-074 - Nylon Fuel Line 5/16 Inch x 10 Ft
Tools & Misc Items Required:
Razor Blade
Heat Gun
Flaring Tool
Caulking Gun
Lubricant
I will go ahead and say that you can use Dorman 800-058(3/8") to fix. However the nylon fuel line included is only 18" long and comes with a double sided barbed fitting. If you use this kit it is two more places to leak. IMO this is patch and not a repair, but I digress. No kit for the 5/16" Return Line.
Expanded View of Nylon Fuel Lines from Rail to Metal Line near Firewall:
Close-up of Quick-Connect Fittings at Fuel Rail:
Close-up Of Metal Lines Near Firewall:
Mmm... STB
You need to relieve pressure at fuel rail first by removing the engine cover, and schrader valve cap. Then put a towel under the valve and use a small screwdriver or the likes to depress the valve to relieve pressure. You will get fuel squirting out.
Schrader Valve Cap:
Schrader Valve:
Next remove the Quick-Connect Fitting from the Fuel Rail. Doh! Didn't get a picture but just squeeze the two plastic pieces and pull up. Again make sure to have a towel handy to soak up any fuel.
Then use a razor blade to cut the nylon off the metal line near the rail: Again Towel To soak Up Fuel
The line is now is now removed.
Cut a piece of nylon fuel line the same length as the OEM line. Should be about 27" IIRC. You will have yours to readily available to match up with.
Now, we need to press the quick connect on to one the nylon fuel line. It is very important that you not kink the line. Some people have had luck heating the tubing with a heat gun or soaking in hot water and pressing on. Dorman recommends using there fancy tool to do this...
I like buying new tools but $100 for a tool I will use a handful of times in life... no thanks. If you don't have a flaring tool or know anyone that does I guess your left with buying the Dorman tool or kinking the lines... I am not saying you can't get a good connection with water or heat gun but this is much more simple and reliable. Most reports online say they almost always kink. Dorman support agrees.
I however, came up with my own solution using a flaring tool and caulking gun. It mimics the Dorman tool perfectly:
Place Fuel Line in Respective Sized Hole in Flaring Tool:
Place in Caulking Gun:
Place Quick-Connect Slighly Lubed In Caulking Gun and Squeeze Until Starts to Insert:
Squeeze Until Fully Seated and Perfectly Pressed: You Will Need to Do This a Quarter of an Inch at a Time to Prevent Kinking!
Quick-Connect Perfectly Pressed; No Crimping of Line:
Perfect New Fuel Line:
To install all you need to do is insert quick-connect fitting on fuel rail. Then heat the end of nylon fuel line a bit wth a heat gun using the flaring tool press the other end of nylon fuel line on to the metal line near firewall 1/4" at a time so you do not kink the nylon fuel line. No pictures but it is self explanatory. There is no way to do the caulking gun idea here nor would the dorman tool work.
You can then ziptie your new line beside the other one. After a few heat cycles it will conform to the old shape. If you try to form it with a heat gun before installation to match the original you will likely kink it.
Enjoy your new fuel line or at least your Aurora will.
Particularly I am replacing the Fuel Feed Line which is the larger 3/8" diameter line. The other line at the fuel rail is the Fuel Return Line. The Return Line is 5/16" in diameter. Both lines can be replaced in similar fashion by using the correct size Quick-Connect fitting and nylon fuel line.
Parts Required:
Fuel Feed Line(3/8"):
Dorman 800-082 - Fuel Line Quick Connector Adapts 3/8 Inch Steel to 3/8 Inch Nylon Tubing
Dorman 800-075 - Nylon Fuel Line 3/8 Inch x 10 Ft
Fuel Return Line(5/16"):
Dorman 800-080 - Fuel Line Quick Connector Adapts 5/16 Inch Steel to 5/16 Inch Nylon Tubing
Dorman 800-074 - Nylon Fuel Line 5/16 Inch x 10 Ft
Tools & Misc Items Required:
Razor Blade
Heat Gun
Flaring Tool
Caulking Gun
Lubricant
I will go ahead and say that you can use Dorman 800-058(3/8") to fix. However the nylon fuel line included is only 18" long and comes with a double sided barbed fitting. If you use this kit it is two more places to leak. IMO this is patch and not a repair, but I digress. No kit for the 5/16" Return Line.
Expanded View of Nylon Fuel Lines from Rail to Metal Line near Firewall:
Close-up of Quick-Connect Fittings at Fuel Rail:
Close-up Of Metal Lines Near Firewall:
Mmm... STB
You need to relieve pressure at fuel rail first by removing the engine cover, and schrader valve cap. Then put a towel under the valve and use a small screwdriver or the likes to depress the valve to relieve pressure. You will get fuel squirting out.
Schrader Valve Cap:
Schrader Valve:
Next remove the Quick-Connect Fitting from the Fuel Rail. Doh! Didn't get a picture but just squeeze the two plastic pieces and pull up. Again make sure to have a towel handy to soak up any fuel.
Then use a razor blade to cut the nylon off the metal line near the rail: Again Towel To soak Up Fuel
The line is now is now removed.
Cut a piece of nylon fuel line the same length as the OEM line. Should be about 27" IIRC. You will have yours to readily available to match up with.
Now, we need to press the quick connect on to one the nylon fuel line. It is very important that you not kink the line. Some people have had luck heating the tubing with a heat gun or soaking in hot water and pressing on. Dorman recommends using there fancy tool to do this...
I like buying new tools but $100 for a tool I will use a handful of times in life... no thanks. If you don't have a flaring tool or know anyone that does I guess your left with buying the Dorman tool or kinking the lines... I am not saying you can't get a good connection with water or heat gun but this is much more simple and reliable. Most reports online say they almost always kink. Dorman support agrees.
I however, came up with my own solution using a flaring tool and caulking gun. It mimics the Dorman tool perfectly:
Place Fuel Line in Respective Sized Hole in Flaring Tool:
Place in Caulking Gun:
Place Quick-Connect Slighly Lubed In Caulking Gun and Squeeze Until Starts to Insert:
Squeeze Until Fully Seated and Perfectly Pressed: You Will Need to Do This a Quarter of an Inch at a Time to Prevent Kinking!
Quick-Connect Perfectly Pressed; No Crimping of Line:
Perfect New Fuel Line:
To install all you need to do is insert quick-connect fitting on fuel rail. Then heat the end of nylon fuel line a bit wth a heat gun using the flaring tool press the other end of nylon fuel line on to the metal line near firewall 1/4" at a time so you do not kink the nylon fuel line. No pictures but it is self explanatory. There is no way to do the caulking gun idea here nor would the dorman tool work.
You can then ziptie your new line beside the other one. After a few heat cycles it will conform to the old shape. If you try to form it with a heat gun before installation to match the original you will likely kink it.
Enjoy your new fuel line or at least your Aurora will.
