Replacing Fuel Tunnel Grommet: A Step-By-Step Guide

Replacing the fuel tunnel grommet in a gas tank is a common maintenance task for vehicle owners. The grommet creates a seal between the fuel lines and the fuel tank, but over time, it can deteriorate and crack, leading to fuel leaks. The replacement process typically involves removing the fuel tank, draining excess fuel, detaching the fuel lines, and carefully prying out the old grommet. A new grommet is then installed, followed by reattaching the fuel lines and refitting the fuel tank. While the steps may vary slightly depending on the vehicle, this procedure helps prevent fuel leaks and ensures the safe and efficient operation of the vehicle.

How to Replace Fuel Tunnel Grommet in Gas Tank

Removing the fuel line grommet

Firstly, you will need to prepare your equipment and the vehicle. Loosen and remove the air cleaner assembly, including the lid and filter. It is important to drain any excess fuel from the tank before proceeding. Once drained, remove the fuel cap and then carefully remove the fuel filter from the fuel line. A sturdy wire, curved into a hook shape, can be useful for this step. Pull the fuel filter out with a twisting and pulling motion.

Now, you will need to remove the fuel lines from the grommet. Pull the return fuel line up and out of the tank grommet, followed by the incoming fuel line and vent line. At this stage, you should be able to carefully pry the grommet out of the fuel tank with a screwdriver.

With the grommet removed, you can now focus on preparing the new fuel line grommet. Lightly coat the edge of the new grommet with a suitable lubricant, such as silicone grease, dialectric spark plug grease, or 2-cycle engine oil. This will help the grommet slide into place more easily.

Finally, you can install the new grommet onto the fuel tank, using a screwdriver if needed to press and seat the grommet into the ridge on the fuel tank. Ensure that it is securely in place before proceeding with any further refuelling or ignition attempts.

It is important to note that this process may vary slightly depending on the specific vehicle and grommet design. Always refer to the manufacturer's instructions or seek advice from a qualified mechanic if you are unsure about any steps or procedures.

Installing the new fuel line grommet

To install the new fuel line grommet, start by lightly coating the edge of the new grommet with 2-cycle engine oil. This will lubricate the grommet, making it easier to install. You can also use silicone grease, dialectric spark plug grease, Vaseline, or alcohol.

Next, install the new grommet onto the fuel tank, using a screwdriver if needed to press and seat it into the ridge on the fuel tank. Make sure the grommet is fully seated and fits as flat as possible against the surface of the fuel tank.

Now, it's time to reinstall the fuel lines. Cut similar angles or tapers on the ends of the fuel lines if they are not already tapered. Tapered endings will allow the lines to slide more easily into the new grommet. Lightly coat the ends of the fuel lines with 2-cycle engine oil or another suitable lubricant.

Insert the fuel vent line into the grommet and feed any excess line into the fuel tank. Repeat this process for the incoming fuel line and the return fuel line, ensuring that all lines are securely in place.

With the new fuel line grommet installed, you can now proceed to reassemble the unit, including reinstalling the fuel filter, fuel cap, and air filter.

Reassembling the unit

Now that you have installed the new grommet and prepared the fuel lines, it's time to reassemble the unit.

Firstly, you will need to reinstall the fuel lines. Check if any of your existing fuel lines have tapered ends. If they do, great! If not, you can use wire cutters or scissors to cut similar angles (tapers) on the ends of the remaining fuel lines. Tapered endings will allow the lines to slide more easily into the new grommet. Lightly coat the ends of the fuel lines with 2-cycle engine oil.

Now, you can start inserting the lines into the grommet. Begin with the fuel vent line. Feed this into the grommet and push any excess or slack line into the fuel tank. Next, insert the incoming fuel line into the grommet and feed any excess into the tank. Finally, insert the return fuel line into the grommet and push any excess into the tank.

The next step is to reinstall the fuel filter. To do this, you will need to use a wire hook to retrieve the incoming fuel line from inside the fuel tank. Once you have the line, use wire cutters or scissors to remove the angle that was added earlier. The tube needs to be squarely cut in order to install the fuel filter. Slide the fuel line clip over the fuel line and position it approximately 1/4 inch from the end of the tube. Now, you can install the fuel filter onto the end of the fuel line. This step should be done in one continuous motion. The ring clip should expand slightly to accommodate the flared connection and then tighten around the narrower part of the fitting. If the ring clip slides backward, simply reposition and start again.

Now, you can reinstall the fuel filter into the fuel tank. Insert the fuel filter and the attached fuel line back into the fuel tank.

The final steps are to reinstall the fuel cap, the air filter, and the air filter lid. Screw the fuel cap back onto the fuel tank. Install the air filter into the air cleaner lid, and then install the lid onto the air cleaner case. Secure the lid with the thumbscrew.

And that's it! You have now successfully replaced the fuel tunnel grommet in your gas tank and reassembled the unit.

Best tools and lubricants to use

To replace a fuel tunnel grommet in a gas tank, you will need a few tools and lubricants to make the process easier. Here is a list of the best tools and lubricants to use:

Tools:

• A pair of channel locks: These are essential for gripping and manipulating the grommet during installation.
• A dull-edged tool: This can help with inserting the grommet without causing damage.
• A hammer: Using a hammer with a piece of dowel rod can help apply even pressure when inserting the grommet.

Lubricants:

• Silicone grease: This is recommended by some tank suppliers and can be found at hardware stores. It helps the grommet slide in easily without damaging the rubber.
• Vaseline: This is a common household item that can act as a lubricant and protect the rubber grommet.
• Alcohol: Applying alcohol to the grommet and fitting can make the installation process smoother.
• WD-40, white lithium, or silicone: These lubricants can be used on the grommet as long as they do not eat away at the rubber.
• Injector oil: This is specifically recommended when pulling a fuel line through the grommet.

It is important to note that some sources advise against using a heat gun on the grommet as it may expand the rubber, making insertion more difficult. Additionally, using a new grommet is recommended as old grommets may have changed shape and will be harder to reinstall.

Safety precautions

To ensure your safety when replacing the fuel tunnel grommet in your gas tank, it is important to take the following precautions:

Firstly, before beginning any work on your gas tank, it is crucial to ensure your safety. Gasoline is highly flammable, so it is important to work in a well-ventilated area, avoid any open flames or sparks, and wear appropriate safety gear such as gloves and eye protection. Completely empty the gas tank and ensure no flammable vapours are present before starting work.

Next, when working with the grommet itself, it is important to use a new grommet to ensure a tight seal and prevent leaks. Old grommets can shrink and change shape over time, making them difficult to reinstall securely. If you must reuse an old grommet, inspect it carefully for any cracks or signs of deterioration, as these can compromise the seal and pose a safety hazard.

Additionally, when installing the new grommet, it is recommended to use a lubricant to help slide it into place. Silicone grease, dielectric spark plug grease, Vaseline, alcohol, or WD-40 can be used without damaging the rubber. Avoid using petroleum-based grease, as it can adversely affect the rubber. Do not use a heat gun to soften the grommet, as this can expand the rubber and make insertion more difficult.

Furthermore, be cautious when working with the fuel line. If possible, remove the fuel line from the grommet before reinstalling the grommet into the tank, as this will make the process easier. If your fuel line has a metal screen or filter attached, be aware that it may be too large to fit through the grommet after the grommet has been installed. In this case, you may need to disconnect the fuel line from the grommet, reinstall the grommet, and then reconnect the fuel line.

Finally, ensure that the grommet is seated flat against the surface of the fuel tank before inserting the final fitting through it. This will help create a tight seal and prevent leaks. Take your time and do not force the grommet into place, as this can damage the rubber and compromise the seal.

Frequently asked questions