Replacing Small Engine Fuel Lines: A Step-By-Step Guide

Replacing the fuel lines of a small engine is a straightforward task that can be completed with relative ease. It is an essential part of small engine maintenance, as old fuel lines can become brittle and prone to breakage over time. The process involves removing the fuel tank cap, draining the fuel, and disconnecting the spark plug for safety. Using pliers, the old fuel lines can be removed from the carburetor, taking note of their orientation. New fuel lines, filters, and clips can be purchased from hardware stores or small engine repair shops. The new lines can then be inserted into the fuel tank and connected to the carburetor, ensuring a secure fit. It is important to use fuel lines made from suitable materials, such as rubber, to prevent degradation and ensure the safe transfer of fuel from the tank to the engine.

How to Replace Small Engine Fuel Lines

Wear gloves and remove fuel from the tank

When replacing small engine fuel lines, it is important to take the necessary precautions for your safety and to ensure a successful outcome. Wearing gloves is one of the first steps to protect your hands from fuel and debris. Gloves will also provide a secure grip when handling tools and components.

Once you have put on gloves, the next step is to remove fuel from the tank. Place a fuel container on a stable surface, such as the ground or a workbench, to collect the fuel. Remove the top cap from the fuel tank and carefully pour the fuel into the container. It is crucial to perform this step before starting any work on the engine to prevent accidental spilling. Additionally, always work in a well-ventilated area and keep open flames or sparks away from the work area.

After draining the fuel, you can proceed with disconnecting the spark plug wire from the spark plug for safety. This step ensures that the engine will not start accidentally during the fuel line replacement process. Now that the fuel is drained and the spark plug is disconnected, you can safely start removing the fuel lines from the carburetor outlets using a pair of pliers. It is important to note the orientation of the small- and large-diameter fuel lines for proper reinstallation.

With the fuel lines removed from the carburetor, you can now focus on extracting the old fuel line and filter from the tank. Using the pliers, grip the fuel line inside the tank and pull it out gently. Continue pulling until the entire fuel line and filter assembly are removed from the tank. At this point, you have successfully removed the old fuel line, and the next step is to obtain a new fuel line and filter from a small engine repair shop or hardware store.

By following these steps, you can safely and effectively remove the fuel from the small engine and prepare for fuel line replacement. Remember to wear gloves, work in a well-ventilated area, and take the necessary precautions to ensure a smooth and safe process.

Disconnect the spark plug wire

Disconnecting the spark plug wire is an important step in replacing small engine fuel lines, and it's crucial to do it properly to avoid any damage. Here's a detailed guide on how to do it:

Locate the spark plug wire: Before you begin, you need to identify the spark plug wire that you'll be working on. It's important to ensure you have access to the boot of the spark plug wire. This is the component that you'll be handling during the removal process.

Don't pull the wire: When dealing with the spark plug wire, it's important to avoid pulling the wire portion itself. Pulling the wire can cause damage, which will then require a replacement. Spark plug wires are delicate, and replacements can be expensive, especially if they are only available in a set.

Grab the spark plug wire boot: Instead of pulling the wire, focus on the spark plug wire boot. Grab it firmly and prepare to twist and pull simultaneously. This action will help break the wire free if it's slightly corroded.

Twist and pull: Once you have a firm grip on the spark plug wire boot, twist it in either direction while simultaneously pulling it off. This twisting motion helps unclip the connection from the top of the spark plug with less strain on the wire.

Apply dielectric grease: To prevent corrosion and sticking, it's a good idea to apply dielectric grease to the terminal on the top of the spark plug. This step can help ensure that future removals are easier and less likely to cause damage.

By following these steps, you can safely disconnect the spark plug wire in preparation for replacing the small engine fuel lines. Remember to exercise caution and avoid pulling the wire directly to prevent any accidental damage.

After completing the fuel line replacement, you can reconnect the spark plug wire by simply pushing it firmly back into place. You'll know it's secure when you feel or hear a clip.

Remove the fuel lines from the carburetor outlets

To remove the fuel lines from the carburetor outlets, you'll need to use a pair of pliers. It's important to note that there are two types of fuel lines: small-diameter and large-diameter. You should remove both of these lines from the carburetor outlets. Here's a step-by-step guide:

• Put on gloves to protect your hands from any debris or fuel residue.
• Using the pliers, grip the small-diameter fuel line at the outlet on the carburetor.
• Gently twist the pliers while pulling the fuel line straight out.
• Repeat this process for the large-diameter fuel line, ensuring you pull it straight out as well.
• Take note of which outlet each fuel line was connected to, as it's easy to mix up the routing when reinstalling new fuel lines.

If the fuel lines are stubborn and difficult to remove, there are a few additional techniques you can try:

• Use a flare nut wrench to grip the nut holding the fuel line in place. This will help prevent rounding off the nut.
• Apply a product like CRC Freeze Off or a mixture of ATF and acetone to the connection. Allow it to soak for a while before attempting to remove the fuel line again.
• If there is a nut on the fuel line, try tightening it just a little before attempting to loosen it. This can help break it free.
• Use two wrenches—one to hold the nut steady and the other to loosen the fuel line.
• If all else fails, carefully cut the fuel line and slice down the centre of the piece that's stuck on the fitting.

Pull out the old fuel line and filter

To pull out the old fuel line and filter, you will need to wear gloves and have a fuel container, pliers, and scissors to hand.

First, place the fuel container on the ground or a workbench. Remove the top cap from the fuel tank and pour any fuel into the container. Remove the spark plug wire from the spark plug for safety.

Now, remove the small- and large-diameter fuel lines from the outlets on the carburetor with the pliers. Pull the lines straight out, noting which outlet each line is removed from.

Insert the pliers into the fuel tank, grip the fuel line, and pull the old fuel line and filter out of the tank. Keep pulling until the entire fuel line is removed from the tank.

You should now obtain a new small-diameter fuel line, a large-diameter fuel line, and a filter from a small engine repair shop or hardware store.

Insert the new fuel lines and test

Now that you have removed the old fuel lines, installed the new fuel filter, and cut the new fuel lines to size, it is time to insert the new fuel lines and perform a test to ensure they are installed correctly.

Firstly, connect the small-diameter fuel line to the outlet on the carburetor from which the main fuel line was removed. Push the line securely onto the outlet. Next, connect the large-diameter fuel line to the remaining outlet on the carburetor. Again, push the end of the line securely onto the outlet.

Now, pour the fuel back into the fuel tank and place the cap on the tank. Reconnect the spark plug wire back to the spark plug.

To test the new fuel lines, place the ends of both lines in 2-cycle fuel (never water) and then prime the bulb. If fuel is pushed out of the unfiltered line, then the orientation is correct. If bubbles emerge from the line with the fuel filter, then the lines have been installed incorrectly and must be switched. In this case, reverse the lines and perform the test again.

Frequently asked questions