Katerina Swanson
Nylon fuel lines are used in cars, often in fuel injection systems. They are lightweight and cheap to manufacture. When adding a new fitting to a nylon fuel line, it is important to ensure a secure, leak-free connection. Some methods to achieve this include using a compression fitting, heating the line with boiling water or a heat gun, or purchasing a specialised repair kit. It is important to exercise caution when working with fuel lines to avoid damage or injury.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Fixing a broken fuel return line elbow | Use a razor blade to cut the line, and attach a new fitting |
| Attaching a new fitting | Buy a dorman kit and press the new fitting on using a clamp block; heat the line with a heat gun or boiling water |
| Boiling water method | Use huge pressure to install; soften the line with hot water and push onto barbs |
| Sealing | Use a copper tube inverted flaring clamp to hold the tubes while driving the steel fittings in |
| Leakage | Use sealants on the brass fitting where it goes into the nylon line |
| Compression fittings | Can be used on nylon fuel lines; use barbed fittings with a compression fitting on one end |
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What You'll Learn
Using boiling water to soften the line
Boiling water can be used to soften a nylon fuel line before press-fitting a union. This is because nylon has a strong affinity for water, and the absorption of water molecules can reduce the stiffness of the material.
To use this method, you will need access to a pot of boiling water and a means of handling the fuel line without burning yourself. It is recommended that you use heat-resistant gloves or tongs to handle the fuel line.
Firstly, bring a pot of water to a rolling boil. You will need enough water to fully submerge the section of the fuel line that you need to soften. Once the water is boiling, carefully place the fuel line into the water and ensure that it is fully submerged. Allow the fuel line to remain in the boiling water for several minutes. The length of time will depend on the thickness of the fuel line and the degree of softening required. It may take some experimentation to get this just right.
One user reported that even after 10 minutes in boiling water, their fuel line was not soft enough to fit the connector. However, this may have been due to access restrictions making it difficult to fully submerge the line. It is important to note that boiling water may not heat the line enough to make a significant difference in stiffness, and other methods such as using a heat gun or hairdryer may be more effective.
Additionally, it is worth noting that the absorption of water can affect the strength and stiffness of nylon materials, so it is important to exercise caution when using this method. The fuel line should not be left in the boiling water for an extended period, as this could potentially weaken the material.
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$14.99
Using a heat gun to heat the line
If you do opt to use a heat gun, be sure to follow safety precautions and have a fire extinguisher to hand. You should also ensure the area is well-ventilated to avoid inhaling any fumes.
When using a heat gun, direct the hot air onto the metal fitting before inserting it into the cold plastic line. This will make the fitting easier to insert. Alternatively, you can use the heat gun to warm the old line fixed in place, pointing upward.
Some people have also had success with heating a 7/16ths deep well socket and slipping it over the outside diameter of the old nylon line stub. Others have tried submerging a tapered centre punch in boiling water and then inserting it into the inside diameter of the old nylon stub.
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Using a hairdryer to heat the line
To use this method, first, cut the line with a razor blade to get a fresh section. Then, use a hairdryer to heat up the line. Once the line is hot enough, quickly fit the connector onto the line before it cools down. It is important to work quickly during this step as the line will start to harden again once it cools down.
Some people have reported that even with a hairdryer, the line may not get soft enough to fit the connector. In this case, you may need to use a different method or tool to install the connector.
Additionally, it is important to note that heating the line with a hairdryer may not be the best method for all types of fuel lines. For example, one user reported that the hairdryer method worked for a 1/4 fuel line but not for a 5/16 fuel line.
Overall, using a hairdryer to heat the line can be an effective method for installing a nylon fuel line press fit union, but it may require some trial and error to get the desired results.
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Using a compression fitting to seal the line
The key to a successful seal is the proper mating angle of the fitting body and the shape of the ferrule. The ferrule must be able to compress properly as the nut is tightened, while maintaining axial alignment with the tubing. The relative angles of the ferrule and the fitting body will determine the level of contact and the amount of linear motion converted into radial compression. A uniform, "line contact" compression around the entire circumference of the ferrule will create the most reliable seal.
It is important to note that over-tightening the compression nut can deform the ferrule too much, creating a "surface contact" and compromising the seal. Therefore, it is critical to follow the manufacturer's instructions for the number of rotations of the nut, as this will ensure proper compression without damaging the components.
Additionally, the tubing should be smooth and free of any roughness or extrusion lines that could create a leak path past the ferrule. It is also recommended to clean the tubing with a fine emery cloth or steel wool to minimize scratches that might cause leaks. For copper tubing, it is essential to flare the end of the pipe after sliding on the components to ensure a secure seal under pressure.
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Using a barbed fitting to connect the line
Using a barbed fitting to connect a nylon fuel line is a common method for creating a secure connection. Here is a step-by-step guide on how to use a barbed fitting to connect a nylon fuel line:
Preparing the Materials and Work Area:
Firstly, ensure you have all the necessary materials, including a replacement nylon fuel line, a barbed fitting specifically designed for nylon lines, and tools such as a razor blade, tin snips, and a heat source like boiling water or a hairdryer. It is also important to work in a well-ventilated area when dealing with fuel lines.
Cutting and Preparing the Nylon Fuel Line:
Using a razor blade or a similar cutting tool, carefully cut the nylon fuel line to create a fresh section for the new connection. Ensure you have enough line to work with and lose about an inch, as mentioned in one of the forums. If there are any access restrictions, you may need to enlarge the access hole using tin snips or similar tools.
Softening the Nylon Fuel Line:
To make the nylon fuel line more pliable and easier to work with, it is recommended to soften it by applying heat. This can be done by submerging the line in boiling water for an extended period, although some people have found this method challenging due to access restrictions. An alternative is to use a hairdryer to direct heat onto the line, ensuring it becomes soft enough to work with.
Connecting the Barbed Fitting:
Once the nylon fuel line is softened, it's time to connect the barbed fitting. Carefully push the softened line over the barbs of the fitting. You may need to use significant force or pressure to get the line all the way onto the fitting. It is important to ensure that the fitting is specifically designed for nylon fuel lines, as mentioned by one user who used a 5/16th brass barbed splice fitting for their hard nylon line.
Securing the Connection:
After the barbed fitting is in place, you may consider using additional methods to secure the connection. Some people have suggested using hose clamps or compression fittings to ensure the line doesn't disconnect. It is also important to check for any leaks after reassembling the components.
While this method can be effective, it is worth noting that some people are not completely satisfied with this fix and continue to seek alternative solutions. Additionally, it is important to prioritize safety and work carefully when dealing with fuel lines to avoid any potential hazards.
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Frequently asked questions
There are several ways to attach a new fitting to a nylon fuel line. One way is to use a repair kit, which involves heating the plastic line with hot water to soften it and then using a special tool to push it over a steel line. Another method is to use a compression fitting, which can be used to join a new line with an existing line. A third option is to use a heat gun or boiling water to heat the line and make it more pliable, but this can be dangerous if done inside a car with the fuel tank open.
Compression fittings are a good option for joining a new line with an existing line, especially if the mating steel line is rust-free. They create a long-lasting, leak-free connection and can accommodate lines that are cut a few degrees off-square.
It may be possible to use a regular steel tube to steel tube union with a nylon compression fitting, but it is recommended to use a nylon-to-steel compression adapter/union for a better fit.
Nylon fuel lines can be challenging to work with. They may crack, and it can be difficult to get a tight seal between the nylon line and fittings. It is also important to ensure that the line is rated for fuel and can withstand the pressure in the lines.
