I screwed up when I was working on pullin the engine out of my 92 cherokee with the 4.0. I was loosening the motor mount bolts,and got my drop light to close to the plastic part of the fuel line that hooks up to the fuel rail from the metal lines,and the light melted holes in them. I looked at a couple online stores and couldn't find a replacement. where can i get another set of lines,and is it possible to just replace the plastic part and not the whole line?
plastic fuel line: where to get?
- Thread starter cjben
- Start date
92DripCherokee
NAXJA Forum User
- Location
- Tampa, Florida
The plastic fuel tubes are an integral part of the fuel line assembly. They're heat shrunk to the steel 5/16 fuel lines.
If you follow the lines under the jeep's driver's side you'll find a second pair of quick-connects. If the OEM parts are still available from the dealer, you could replace the section of fuel line as an assembly, forward of these "middle" quick-connects. It will include the fittings and retainers that attach to the fuel rail. At least $40 for just one line.
My return line fitting cracked after my recent header swap, so I just made my own fuel hoses. That's another story.
If you follow the lines under the jeep's driver's side you'll find a second pair of quick-connects. If the OEM parts are still available from the dealer, you could replace the section of fuel line as an assembly, forward of these "middle" quick-connects. It will include the fittings and retainers that attach to the fuel rail. At least $40 for just one line.
My return line fitting cracked after my recent header swap, so I just made my own fuel hoses. That's another story.
Last edited:
92DripCherokee
NAXJA Forum User
- Location
- Tampa, Florida
here's a CJ with some quick connect bypasses, I like these even more than my plumber's special. They are true quick connects. They almost look like Dorman help parts right off the shelf, hmm.
http://www.cjoffroad.com/forums/topic.asp?TOPIC_ID=11732
Go jeep made a splice too, but he's lucky, his fuel rail supply nipple is 5/16! Exactly the same OD as the steel fuel line
http://www.go.jeep-xj.info/HowtoAFPR.htm
I figured it would be easy to get some SAE 30R9 fuel injection hose, and make a simple splice. But, the fuel supply nipple on the 92 4.0L fuel rail is 3/8, and the steel fuel line is 5/16. No match.
I would never try to slip 5/16 FI hose over a 3/8 fitting. It will split eventually.
So I made a brass adapter to couple the smaller fuel line to the larger fuel rail.
Courtesy of Lowe's, I made the first adapter as follows
1/4 NPT male with a 5/16 barb
1/4 NPT male with 3/8 barb
1/4 NPTdouble female coupler
1 section of 3/8 FI hose
1 section of 5/16 FI hose
lots of 3/8 and 5/16 clamps, 2 per connection
The 3 piece 1/4 NPT adapter was too heavy, and long for the space. The extra weight of the 1/4 NPT brass caused the hoses to bounce and flex, not good. I drove it for a month before I decided it was too risky.
I got serious on the second try and mail ordered a 1/8 NPT hardware, for its lighter weight, and shorter length. No stores in my area had 1/8 hardare, not even NAPA, so I ordered from fittingsandadapters.com.
The new 1/8 NPT coupler was two-piece, and much lighter.
1/8 NPT female with 3/8 barb
1/8 NPT male barb with a 5/16 barb
Got the correct loctite for fuel systems, and tightened the shit out of the adapter. It leaked a week later, the brass cracked. Very scary, never overtighten brass fittings!
The third one is a charm. I used the same 1/8 npt brass hardware again, but tightened it just to "yield". And as always, double-clamped the connections. In total, I've built 4 of these splices for the fuel supply, so if you have any questions let me know.
I got the initial idea from xjtrailrider in this thread
http://www.naxja.org/forum/showthread.php?t=103650&highlight=fuel+line
He didnt use an adapter though, not sure how pressure tight his version was.
I thought of the brass adapter to make the splice inexpensive, pressure tight, and safe, and it is. The two biggest lessons learned were 1/4 NPT is too heavy for unsupported connections, and tapered NPT fittings should be torqued carefully, with gasoline-rated white loctite for thread sealant, no teflon tape.
http://www.cjoffroad.com/forums/topic.asp?TOPIC_ID=11732
Go jeep made a splice too, but he's lucky, his fuel rail supply nipple is 5/16! Exactly the same OD as the steel fuel line
http://www.go.jeep-xj.info/HowtoAFPR.htm
I figured it would be easy to get some SAE 30R9 fuel injection hose, and make a simple splice. But, the fuel supply nipple on the 92 4.0L fuel rail is 3/8, and the steel fuel line is 5/16. No match.
I would never try to slip 5/16 FI hose over a 3/8 fitting. It will split eventually.
So I made a brass adapter to couple the smaller fuel line to the larger fuel rail.
Courtesy of Lowe's, I made the first adapter as follows
1/4 NPT male with a 5/16 barb
1/4 NPT male with 3/8 barb
1/4 NPTdouble female coupler
1 section of 3/8 FI hose
1 section of 5/16 FI hose
lots of 3/8 and 5/16 clamps, 2 per connection
The 3 piece 1/4 NPT adapter was too heavy, and long for the space. The extra weight of the 1/4 NPT brass caused the hoses to bounce and flex, not good. I drove it for a month before I decided it was too risky.
I got serious on the second try and mail ordered a 1/8 NPT hardware, for its lighter weight, and shorter length. No stores in my area had 1/8 hardare, not even NAPA, so I ordered from fittingsandadapters.com.
The new 1/8 NPT coupler was two-piece, and much lighter.
1/8 NPT female with 3/8 barb
1/8 NPT male barb with a 5/16 barb
Got the correct loctite for fuel systems, and tightened the shit out of the adapter. It leaked a week later, the brass cracked. Very scary, never overtighten brass fittings!
The third one is a charm. I used the same 1/8 npt brass hardware again, but tightened it just to "yield". And as always, double-clamped the connections. In total, I've built 4 of these splices for the fuel supply, so if you have any questions let me know.
I got the initial idea from xjtrailrider in this thread
http://www.naxja.org/forum/showthread.php?t=103650&highlight=fuel+line
He didnt use an adapter though, not sure how pressure tight his version was.
I thought of the brass adapter to make the splice inexpensive, pressure tight, and safe, and it is. The two biggest lessons learned were 1/4 NPT is too heavy for unsupported connections, and tapered NPT fittings should be torqued carefully, with gasoline-rated white loctite for thread sealant, no teflon tape.
Last edited:
92DripCherokee
NAXJA Forum User
- Location
- Tampa, Florida
those look like the same fuel injection clamps you'll find at Advance, or Vatozone.
I think xjtrailrider ran 3/8 hose from the fuel rail to the 5/16 steel fuel line, and likely clamped it hard to close the gap. You might PM him, he answered a question for me about his quick connect elimination a few months back.
I think xjtrailrider ran 3/8 hose from the fuel rail to the 5/16 steel fuel line, and likely clamped it hard to close the gap. You might PM him, he answered a question for me about his quick connect elimination a few months back.
Last edited:
92DripCherokee
NAXJA Forum User
- Location
- Tampa, Florida
The simplest and safest but most expensive option? OEM tube and hose assemblies from Jeep. These part numbers are from the 91-93 part catalog
http://www.xjjeeps.com/com_xjjeeps/tech_reference.asp?section=2&ID=27
return- 5200 4871
supply- 5200 4873
if you type these numbers into a site like chryslerpartsdirect.com, they old pn's are superceded by new pn's.
return- 52018416. $35.06
supply- 52018417 $34.28
not bad for a prices, but the local stealership may mark these parts up.
http://www.xjjeeps.com/com_xjjeeps/tech_reference.asp?section=2&ID=27
return- 5200 4871
supply- 5200 4873
if you type these numbers into a site like chryslerpartsdirect.com, they old pn's are superceded by new pn's.
return- 52018416. $35.06
supply- 52018417 $34.28
not bad for a prices, but the local stealership may mark these parts up.
