Nylon Fuel Line Repair

1. Relieve the fuel system pressure refer to Service And Repair/ Fuel System Pressure Relief Proceedure.

Nylon Tube Splicing:

2. Cut out the damaged section of tubing and retain as a guide.

3. Cut a section of service tubing (type 11 or 12 nylon 7.9mm [5/16 in] diameter) to same length as the damaged section of tubing.

NOTE: To make a hand insertion of barbed connectors into nylon tubing easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon.

4. Select proper 7.9mm (5/16 inch) barbed connectors for completing a splice. Two connectors are required for each splice.

5. Install the barbed connectors into each end of the replacement tubing using boiling water as outlined.

6. Install the clips onto any of the tubes which might be difficult to access once the final splices are completed.

7. Install the four keystone clamps loosely onto the original nylon tubing before beginning next step.

8. Complete the splice of replacement nylon tubing to original nylon tubing at both ends.

9. Tighten the clamps.

10. Install any remaining clips which were removed for this service and check that the tubes are secure in the original clips.

11. Fill the fuel tank, start the engine and check for leaks.