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Old 01-25-2012, 05:39 PM   #1
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fuel line fittings.... need help

Hey guys, I've got a 91' yj 4.0, but i think this is a generic question and I'm hoping to get a better response by opening this up to everyone.

i did a comple rebuild of my engine, and now have everything back together except the fuel pressure regulator and the 2 fuel lines coming from the tank ( this have quick disco's on them). i cannot find anywhere that tells me what 2 o-rings (size, specs, or part #'s will do) for the fuel pressure regulator, or the quick disconnect.

also, on the disconnects, how many o-rings are inside of those things? i already pulled 2 out of each and it looks like there may be 1 more in each. should i have just left them alone and hooked them back up as is? i can't find any info about these disco's other than i think one is 3/8 and one is 5/16. At advanced auto, they have kits to replace the disconnects, but they've all got that nylon flex tubing on them ( like whats in the jeep) and i've never messed with that stuff and don't know what it entails. is it easy to work with that stuff or are their special tools needed or what?

if i can't find the o-rings or how to just replace those fittings completely, i'm thinking of just cutting the the nylon section and disco out completely and using flexible fuel line with a clamp on each end ( fuel rail and hard line coming from the tank). does anyone see any problem with this? would it hold the pressure or be likely to slip off?

any and all help is greatly appreciated. TIA

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Old 01-25-2012, 07:28 PM   #2
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Not sure what size o-rings those use, but if you go the route of just eliminating those disconnects and using fuel line e aware that there is normal fuel line and high pressure line, you'll need the high pressure type with a fuel injection fuel pump.

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Old 01-25-2012, 08:48 PM   #3
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i was planning on using high pressure if i go that route. i'd prefer to keep it factory. i'm more concerned that if i just clamp HP fuel line on there it may pop off at some point. and i dont want that
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Old 01-25-2012, 08:52 PM   #4
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Yeah, you need to put a flare on the line if you use regular fuel line and a clamp. I'll do some searching and see if I can find anything on the factory disconnects.
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Old 01-25-2012, 09:08 PM   #5
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thanks bud, i've done a good bit of searching but to no avail.
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Old 01-25-2012, 09:32 PM   #6
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OK, after some looking...seems those disconnects are not designed to be repaired, just replaced. The factory o-rings are most likely viton, not what you'll find in the average o-ring kit. Looks like the choices are either buy the disconnect pigtail or go with high pressure rubber fuel line...personally I'd just go with fuel line. If you don't have a flaring tool, at the least push the new rubber line onto the metal tubing a good 6 inches and use two clamps, one about a half inch from the end of the rubber line and and the second about an inch back from where the metal line ends inside the rubber line, just tighten them down good and snug and you should be fine.
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Old 01-25-2012, 09:52 PM   #7
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10-4, thanks bud. they weren't viton o-rings. i've seen the repair kits at autozone, but they have that nylon hose stuff and i have no clue how to work with that stuff, it may be just as simple a heat gun to shrink fit it, but idk, i'll do some looking.
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Old 01-25-2012, 10:21 PM   #8
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yea, i just did some looking, you need a special ($100) tool to press fittings into those nylon lines. thats not worth it. i'll just remove the lines. put a flare on the hard lines coming from the tank put a HP fuel line over each hard line several inches and 2 hose clamps. my flare tool wont fit on the nipples coming off the fuel rail, they're too close to each other, but they already have a lip on them ( where the original connectors catch), i'll try and stretch the line over those lips. and put a clamp on each side of said lip. should be good to go. now i need find HP fuel line in town...... push come shove i'll go with some aircraft quality lines ( dad's a mech and has some in is hangar i believe)
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Old 01-25-2012, 11:02 PM   #9
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i'm having trouble finding a high pressure fuel line that will fit my needs. it's got to be flexible and able to work with a hose clamp or something similar. you have any ideas? the best i can find is something from autozone that says its minimum burst is 50psi. i dont think the jeep is working that high. but its probably close to that. idk if i want to risk it. any ideas?

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