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Old 06-27-2013, 02:15 PM   #1
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Default Repairing leaking nylon fuel line.

I tried to find an appropriate area for fuel issues, but I did not see one anywhere, so I am posting this here.

I found I had a hole in my nylon 3/8" fuel line coming from the tank, going to the fuel filter, I was able to crawl under there without a need to jack it up, and I removed the line, I brought it in and tried to use one of these to repair it temporarily.
Dorman 800-193 3/8" Fuel Line Connector, (Pack of 2) : Amazon.com : Automotive Dorman 800-193 3/8" Fuel Line Connector, (Pack of 2) : Amazon.com : Automotive

But, I found those type of unions are worthless for the fuel line, I tried two different ones, and I made sure the ends were perfect before inserting the fuel line into it.
It would leak from that union no matter what I did, so I brought the line in, let it sit for vapors to dissipate, then I got a brass union, and my torch, I set the torch to as low as I could, and then held the line about 2" from the flame, kept rotating it a bit, and then pressed it onto the brass union, it was not as hard as I thought it would be to marry the line to the brass union on both ends, but I got it on there, pressurized the system to find no leaks.
Below is a link to the repair kit I bought that had the brass union in it, I am pretty sure you can buy the union by itself, but I felt marrying the union to the new line was better than marrying it to the old line.
Amazon.com: Dorman 800-058 Nylon Fuel Line Repairkit: Automotive Amazon.com: Dorman 800-058 Nylon Fuel Line Repairkit: Automotive

I did notice I also had a hole in the EVAP line, I may see if I can get to it to remove it so I can use a brass union as well, but if I cannot I am considering using some rescue tape.
Rescue Tape RP2562 MCLF Fusing Silicone Repair Tape, 12' Length x 1" Width, Black: Amazon.com: Industrial & Scientific Rescue Tape RP2562 MCLF Fusing Silicone Repair Tape, 12' Length x 1" Width, Black: Amazon.com: Industrial & Scientific

Welcome to Rescue Tape! | Main | Rescue Tape

It sounds like it should be sufficient for the EVAP line, as well as for a pressurized line, so it should be good enough to seal the little holes in the EVAP line.
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Old 06-27-2013, 02:31 PM   #2
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Nice work. Keep a close eye on it for a while for leaks.
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Old 06-27-2013, 02:41 PM   #3
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you dont have to take it off the car just make a coffee cup of hot water and dip the end in it for a while, then get the brass barbed fitting and jam it on there
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Old 06-27-2013, 02:43 PM   #4
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Thanks Roy, I will be sure to keep an eye on it for a while, especially since when it was leaking before it was spraying out near the cat/exhaust area, the last thing I was to do is blow up while driving.

I mainly posted this because I wanted to be sure others did not try to take the easy way of trying to repair it like I did, I choose those nylon compression unions because I have used them a lot in plumbing, and I thought they could withstand the fuel pressure, I suggest anybody with a leaky fuel line avoid this nylon Dorman union like the plague!



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NOTE: I bought the correct 3/8" sized unions, it says 5/16 because it was the product image Amazon used for all of the unions.
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Old 06-27-2013, 02:51 PM   #5
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Quote:
Originally Posted by jwfirebird View Post
you dont have to take it off the car just make a coffee cup of hot water and dip the end in it for a while, then get the brass barbed fitting and jam it on there
I watched a few videos of a guy trying to dip it in hot water for a while, he was unable to marry them only using hot water, also if I had not removed it I'd not have had room to get a cup of hot water under there, even if I had jacked it up.
I tried almost boiling hot water the last time, and the line would cool before I could get it pressed all the way on.
As long as you are careful, and do not directly contact the nylon with the flame, then the blow torch, or lighter method works much easier/faster.
When you look at the way the line is on the union, it looks just like it does on the factory fittings.

Now if you are having to make a small degree bend in the nylon line, sitting it in some hot water would work perfectly, for larger degree bends I read that sometimes inserting a metal clothes hanger into the line, then heat, and bend it.
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Old 06-27-2013, 02:57 PM   #6
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WARNING, always use safety glasses, I could not find mine, and proceeded anyway, and the second I touched that fuel filter it had one last drop saved for my eye, gas in the eye is NOT a good thing, burns quite a bit, had to immediately flush my eye out.

Also, always be extremely careful working around fuel/fuel vapors, I only use LED lights for lighting, and NEVER get a flames near gas, or gas vapors.
I would not even trust using a hair dryer like I have seen some say they used, that is dangerous!
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Old 06-27-2013, 03:29 PM   #7
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It worked fine for me.if it gets tight you could try some dish soap. i had to do the tank to filter line on my old monte seemed much easier than taking it apart because if you mess with those ends you have a 50% chance on whether its going to leak when you put it back together, plus the obvious hazards of lighting fumes or just melting the line so you have to go buy more anyway
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Old 06-27-2013, 04:18 PM   #8
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Justin, I am not sure I totally understood what you were trying to say about the lines having a 50% chance to leak.
Are you saying using the brass unions will cause the leak, or that heating them with indirect heat from a flame will?
There is no hazard using a flame to heat the nylon hose if you have it inside way away from any fuel, and as long as you let the line air out for a bit, and if you know what you are doing with keeping it far enough from the flame, then you won't warp the fuel line at all.

Wait, I think I know what you are saying, messing with the quick connect ends will cause it to leak?
I used new ends on each side, which has new o-rings inside where the quick connector connects, it should not leak at all, so far so good.
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Old 06-27-2013, 04:36 PM   #9
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yep the quick connect if you are using new you should be fine but if taking off to repair then reinstalling, those will leak about half the time i have tried it
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Old 06-27-2013, 05:48 PM   #10
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Quote:
Originally Posted by jwfirebird View Post
yep the quick connect if you are using new you should be fine but if taking off to repair then reinstalling, those will leak about half the time i have tried it
Ahh ok, thanks for the tip Justin , glad I am going with a new quick connect on each end.
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