Fuel Line Coupler: Service and Repair

QUICK-CONNECT FITTING

REMOVAL
When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.

1. Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure.
2. Disconnect negative cable from battery or auxiliary jumper terminal.
3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube.

INSTALLATION

CAUTION: Make sure that the O-ring in installed in fitting. Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly push-pulling-push on fuel tube and fitting to ensure it is secured.

1. Using a clean lint free cloth, clean the fuel tube nipple and retainer.
2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean engine oil.
3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard.

Plastic Quick-Connect Fitting/Fuel Tube Connection:

4. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed. Do not rely upon the audible click to confirm a secure connection.
5. Connect negative cable to battery or auxiliary jumper terminal.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for several minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

6. Use the DRB III(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

TWO-TAB TYPE FITTING

Typical Two-Tab Type Quick-Connect Fitting:

This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced.

CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.

DISCONNECTION/CONNECTION
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly.
4. To disconnect quick-connect fitting, squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body.
5. Inspect quick-connect fitting body and component for damage. Replace as necessary.

CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage.

6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard.
8. Verify a locked condition by firmly push-pulling-push on fuel tube and fitting (15-30 lbs.).
9. Connect negative cable to battery or auxiliary jumper terminal.
10. Use the DRB III(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

PLASTIC RETAINER RING TYPE FITTING

Plastic Retainer Ring Type Fitting:

This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color.

CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.

DISCONNECTION/CONNECTION
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly.
4. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection.
5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body.
6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary.
7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
8. Insert quick-connect fitting into component being serviced until a click is felt.
9. Verify a locked condition by firmly push-pull-ing-push on fuel tube and fitting (15-30 lbs.).
10. Connect negative battery cable to battery or auxiliary jumper terminal.
11. Use the DRB III(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.