Another fuel line question

[Dean Abramson]

The fuel return line from my injectors to the tank was cracked. I have (almost) fitted a new one, and also I have replaced the little return hoses which went between the injectors.

My biggest issue is that at the tank end, the nipple on the tank faces the friggin bulkhead at about a 45 degree angle, in an impossible location, with less than an inch of clearance. There is just enough room for the hose's curve, once the new hose is on. But so far, it has been impossible for me to get the new hose on. (I had to cut/slit the old one off.) There is just no room to work. I can just manage to get the end of the hose on to the very end of the nipple, but I can not get it on any further. I heated the hose pretty hot with a hair dryer, but no dice. The problem is that I (facing forward in the port cockpit locker) cannot get a grip on the hose to push; I actually have to pull, with just a thumb and one finger. The area is very inaccessible and crowded with other stuff.

I am phobic about contaminating my fuel, but would it be okay to put some grease on the nipple? If so, what kind? Vaseline, motor oil, winch grease?

Any special techniques for doing this? I tried a pliers on the hose, but all I seemed to do was abrade the hose, and I made no progress pulling it on.

One idea I had is to create a pigtail. The return line is 1/4" ID. If I got, say, a 6" piece of 3/8" hose on to the nipple, and then clamped the living daylights out of it, could I then step down with an asymmetrical double-barbed fitting? (It would be stepping up in the direction of fuel flow.) But this does not sound like a great idea, even to me.

My preference is to get the right size on, of course. I cannot turn the fitting on the tank. Clockwise would really help, but I assume that the fitting is already in there plenty tight, and I really, really don't want to break it. Counter-clockwise would just make it run into the outbound hose and fitting.

Like I said in the other post, HELP!

Thanks,

Dean

[Russell]

The fuel return line from my injectors to the tank was cracked. I have (almost) fitted a new one, and also I have replaced the little return hoses which went between the injectors.

My biggest issue is that at the tank end, the nipple on the tank faces the friggin bulkhead at about a 45 degree angle, in an impossible location, with less than an inch of clearance. There is just enough room for the hose's curve, once the new hose is on. But so far, it has been impossible for me to get the new hose on. (I had to cut/slit the old one off.) There is just no room to work. I can just manage to get the end of the hose on to the very end of the nipple, but I can not get it on any further. I heated the hose pretty hot with a hair dryer, but no dice. The problem is that I (facing forward in the port cockpit locker) cannot get a grip on the hose to push; I actually have to pull, with just a thumb and one finger. The area is very inaccessible and crowded with other stuff.

I am phobic about contaminating my fuel, but would it be okay to put some grease on the nipple? If so, what kind? Vaseline, motor oil, winch grease?

Any special techniques for doing this? I tried a pliers on the hose, but all I seemed to do was abrade the hose, and I made no progress pulling it on.

One idea I had is to create a pigtail. The return line is 1/4" ID. If I got, say, a 6" piece of 3/8" hose on to the nipple, and then clamped the living daylights out of it, could I then step down with an asymmetrical double-barbed fitting? (It would be stepping up in the direction of fuel flow.) But this does not sound like a great idea, even to me.

My preference is to get the right size on, of course. I cannot turn the fitting on the tank. Clockwise would really help, but I assume that the fitting is already in there plenty tight, and I really, really don't want to break it. Counter-clockwise would just make it run into the outbound hose and fitting.

Like I said in the other post, HELP!

Thanks,

Dean

Why not just remove the tanks return line fitting and install a new one? Facing the direction you need it of course. It sounds like you are creating more problem trying to use the existing fitting then is worth bothering with. Plug the fitting, drill and tap a new hole and install a new fitting that works for what you need.

It sounds like you are using the wrong sized hose though. When I bought my boat I had to replace all the fuel lines, they were all cracked, I didnt have any issues. But if it slides onto the fitting on the engine, but not onto the tank, thats odd. Find what fits on the engine side (harder to change) then buy a 90 degree fitting for the tank side and install it, it will take minutes rather then driving yourself nuts with heat guns, angles and lube. Remove the old return and plug it with an aluminium screw (if you have to cut the old return off then drill and tap for said screw).

[Dean Abramson]

Russell, what you suggest is something I have no experience or confidence with. Nor do I have the needed tools. Kind of "above my pay grade." (I realize that this is something I ought to learn about.)

But in any event, I am pretty sure that I do not have the space to do that. I should have mentioned that the tank fittings are right up under the deck, in addition to right by the bulkhead. Also, access is badly hindered by the placement of the hot water tank just abaft the fuel tank. Maybe I can get a photo today; it is hard to explain.

I have gotten it on about a quarter of an inch, but just cannot grip it properly to slide it the rest of the way.

Will a little grease hurt anything? I am sure that I have the right hose size; it is the awkwardness of the job that is the issue. I think that some grease could get me over the hump.

Would a little teflon grease (WIGL), just at that spot, really potentially give me fuel issues? 90% of the grease will stay between the interior hose walls and the nipple, but admittedly, a very tiny bit would no doubt come into contact with the fuel.

Dean

[Dean Abramson]

This will explain things better:

[img]http://www.mainephoto.com/folios/FuelLine110502-3.jpg[/img]

[img]http://www.mainephoto.com/folios/FuelLine110502-10.jpg[/img]

You can see that I have gotten the hose on just the end. That is as far as I could get it.

Dean

[JWSutcliffe]

Dean:

I would try some heat first. Heating the hose with a heat gun will soften the rubber, allowing you to more easily stretch it over the fitting, but not leave it still slippery on the inside like grease of any sort will. However, as a last resort I wouldnt worry about using a little petroleum-base grease or vaseline (i.e. soluble in diesel fuel.)

[Michael Abramson]

Abe,

I see from the photo what the issue is. Here is what I would try.

Use a dab of petroleum based grease on the barb of the fuel nipple. In the minute amount you will use, it can't harm your fuel.

If the barb is 1â€