Mercedes Mullins
When it comes to running fuel lines in a Subaru, there are several factors and procedures to consider. One key consideration is whether to run the lines in series or parallel, with opinions varying among mechanics and tuners. Additionally, the type of fuel line used is important, with some recommending against using PTFE due to its lack of expansion and contraction properties. Lubrication and heating can aid in the installation process, making it easier to fit new fuel line bits. Furthermore, it is crucial to be mindful of how the fuel lines are routed to prevent kinking or pinching, which can lead to reduced fuel output and potential engine issues. Proper clamp placement and tightness are also essential to prevent fuel leaks, especially in cold temperatures.
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What You'll Learn
How to fix a leaky fuel line
If you have a leaky fuel line in your Subaru, the first step is to locate the source of the leak. In Subarus, the most common sources of leaks are the two rubber lines that run under the turbo inlet. These rubber lines can become hard and brittle over time, causing them to leak. Another common source of leaks in Subarus is the fuel line itself, which may have been manufactured slightly smaller than intended. This issue typically only becomes apparent during extreme cold, as freezing temperatures can cause the factory rubber fuel lines to shrink and leak.
Once you have located the source of the leak, you can begin the repair process. If the leak is coming from the two rubber lines under the turbo inlet, you will need to remove the clamps from the ends of the hoses and use a razor blade to cut a slit on both sides of the hose for easy removal. Next, you'll want to cut your new hoses to size, slide them over both sides of the hardlines, and install the clamps to secure them in place.
If the leak is coming from the fuel line, you may need to replace it. To do this, start by opening the tray to the left of the steering wheel and releasing the hinge on the bottom of the tray to access the internal fuse box. Remove the 15-amp fuse for the fuel pump and try to start the car to relieve the fuel pressure. Remove the air intake and the spark plug wires, and set them aside. With these components out of the way, you will be able to access the leaky fuel line.
To replace the fuel line, cut the old line using a razor and coat the new metal fuel line with a lubricant. Slide the new fuel line onto the metal line and past the barb, and secure it in place with hose clamps. With the new fuel line in place, reconnect the spark plug wires and put the fuel pump fuse back. Start the car and check for any leaks. If no leaks are detected, you can replace the cover and the intake.
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Whether to run fuel lines in series or parallel
Whether to run fuel lines in series or in parallel is a debatable topic. Tuners seem to prefer parallel, while mechanics and shops think series is good until 600 whp and above. The difference between the two comes down to the length of fuel travel to each injector. Ideally, these flow lengths should all be the same, but if they cannot be, minimising the longer travel lines is best. Parallel would mean a much more equal length, whereas in series, the injectors are fed one after the other.
The factory system runs the injectors in series, thus cylinders 3 and 4 are at the end of the fuel delivery. Aftermarket systems run parallel fuel blocks to provide equal distribution to all cylinders at the same time. Keeping parallel lengths equal helps ensure equal return volume, but this might not matter. It also helps ensure that if you have solved any resonance issues on one side, the other is the same and not on the verge of problems.
Some people choose to run a dead-head fuel system, where the ends of the rails are capped off, pressure is applied to the rails, and the FPR is before the rails. However, this means the fuel will have more time to heat up, sitting in the rails instead of continuously flowing through and cycling back through the tank. It is also recommended not to run PTFE between the filter and the FPR because it behaves as a hard line and has no expansion/contraction properties. Nitrile fuel hoses act as a dampener in the system, helping to even out the pulsations.
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How to remove the old fuel line
To remove the old fuel line, start by relieving the fuel pressure. Open the tray to the left of the steering wheel and pull up to release the hinge on the bottom of the tray. Remove the 15-amp fuse from the internal fuse box, then try to start the car. This will relieve the fuel pressure so that when you remove the fuel line, fuel won't spray out. There will still be some fuel that dribbles out.
Next, remove the air intake. There are two 10mm bolts on the front of the intake and one 10mm nut that need to be removed. The intake will then simply pull out from the air box at the back of the engine. With the intake out of the way, you will be able to access the cover that hides the leaky fuel line.
Remove the spark plug wires from the coil pack on top of the engine and set them aside. Be careful not to flex the metal fuel line too much to avoid causing a pinch or break in the line. Remove the two 10mm bolts that support the two power hard lines, and the 12mm bolt that holds the cover to the intake manifold.
Look lower on the cover and you will see two 12mm bolts that hold the cover in place. Once these bolts are removed, you can then remove the cover and set it aside. Pay attention to the hole on the cover that faces the radiator, as this is where you will be able to tighten the clamp without having to remove the cover in the future.
At this point, you should be able to access the old fuel line. Use a razor to cut the old fuel line off, as it can be nearly impossible to remove otherwise.
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How to fit a new fuel line
To fit a new fuel line, you will first need to relieve the fuel pressure. Do this by pulling the fuel pump fuse, removing the gas cap, running the car until it stops, and then disconnecting the battery. There will still be some fuel in the line, so be careful when removing the old fuel line. One user recommends using a razor to cut the old line off.
Next, you will need to remove the air intake. There are two 10mm bolts on the front of the intake and one 10mm nut that need to be removed. You will also need to remove the spark plug wires from the coil pack on top of the engine. Remove the two 10mm bolts that support the two power hard lines, and the 12mm bolt that holds the cover to the intake manifold.
Now you will be able to access the fuel line. Cut a piece of 5/16 fuel line that is about 4 inches long. Flex the long metal fuel line out slightly and coat it with a lubricant. Slide the new fuel line onto the metal fuel line and past the barb, until you can put the new fuel line onto the short 90-degree end. Slide the hose clamps onto the fuel line and position them for final fitting. Put one clamp vertical and one horizontal on top of the replacement line. Slide the line into place and tighten the clamps.
Finally, replace the hose that goes in front of the fuel line. Reconnect the spark plug wires and put the fuel pump fuse back into place. Check for leaks by starting the car and letting it run for a little while.
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How to prevent fuel lines from kinking or pinching
Preventing kinking or pinching of fuel lines in a Subaru requires careful maintenance and, in some cases, replacement of the fuel lines. Here are some tips to help prevent these issues:
Use Proper Materials: Fuel lines should be made of reinforced plastic or specialized fuel injection lines to withstand physical impact and environmental factors that could cause kinking or pinching. Avoid using regular fuel lines as they are more susceptible to damage.
Maintain Flexibility: The metal fuel line that runs to the center of the engine can move and bend. Avoid flexing it excessively to prevent pinching or breaking. Apply lubricant to this line and ensure it has sufficient flexibility to reduce the risk of kinking.
Replace Vulnerable Components: Some Subaru models, particularly the 2004 Subaru Forester XT, are known to have leaking fuel line issues due to manufacturing variations. Consider ordering new fuel lines from Subaru to address any inherent vulnerabilities and reduce the likelihood of kinking or pinching.
Use Appropriate Tools: When bending fuel lines, use appropriate tools like a spring-type or lever-action bender. These tools help prevent kinking and provide better control over the bending process. Simple benders, while cheaper, have a higher chance of ruining tubing and are less effective in securing complex bends.
Regular Maintenance: Proper maintenance is crucial to prevent fuel line issues. After replacing a fuel line, inspect every connection, check hoses for leaks or breaks, and regularly examine vulnerable spots for potential damage. This proactive approach can help identify and address problems before they escalate.
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Frequently asked questions
Use a razor to cut off the old fuel line.
Make sure the hose clamps are tightened.
It is recommended to run them along the underbody and up the firewall.
Running fuel lines in series means that one rail is fed and then the others, whereas running them in parallel means that both rails are fed at the same time off of a split.
Pull the fuel pump fuse, remove the gas cap, run the car until it stops, and then disconnect the battery.
