When To Replace Fuel Lines: Signs And Symptoms

Fuel lines are an essential component of any vehicle, but like any other component, they are susceptible to wear and tear. Over time, fuel lines can become corroded or damaged, leading to leaks and potentially dangerous situations. While it may not be necessary to replace fuel lines frequently, it is important to regularly inspect them for any signs of deterioration and replace them if needed. This article will explore the factors that contribute to fuel line degradation and provide guidance on when and how to replace them.

Fuel line replacement cost

The cost of replacing a fuel line varies depending on the vehicle, the number of lines that need to be replaced, and the location of the broken lines. Most fuel line replacements cost around $300 to $500, but prices can range from as little as $150 to more than $2,000.

For example, the replacement of three fuel lines on a 1999 Oldsmobile Cutlass was quoted at $3,000 for a full replacement or $1,500 to cut out and replace the rusted sections. Another user reported being charged $1,500 to replace the fuel lines on their 2005 GMC Sierra 1500, while someone else paid the same amount to replace just a section of the line on their 2016 Kia Sorento.

It is worth noting that fuel line replacement can be a complex task, and attempting to repair only a portion of the line may not always be advisable, as corrosion elsewhere could cause another leak. In some cases, it may be necessary to lift the bed or drop the tank to access the fuel lines, adding to the labour cost.

One option to reduce costs is to attempt the replacement as a DIY project. This will require some specialised tools and knowledge, but can be a cost-effective solution, with the parts themselves costing around $100 or less.

When considering fuel line replacement, it is also worth checking if your vehicle is covered by any warranties, as most factory bumper-to-bumper warranties include fuel lines, and your vehicle may also qualify for a special CARB emissions warranty if you are in certain states. However, it is important to note that warranties typically do not cover physical damage, which is the leading cause of fuel line failure.

Signs to look out for

The fuel lines in vehicles are routed in a way that ensures they are not located in a crumple zone in case of an accident. However, as vehicles are lasting longer, the chances of fuel lines leaking are increasing. The main reasons for metal fuel line failure are corrosion and damage from abrasive materials, debris, and mounting brackets.

• Lack of fuel in the combustion chamber: This can cause the car not to start or to stall soon after starting.
• Noticeable fuel odour: A strong smell of fuel coming from the vehicle could indicate a leaking fuel line.
• External damage: Inspecting the fuel lines for any signs of cracking or dry rot is important, especially if they are older.
• Age: While the lifespan of fuel lines varies depending on the vehicle and conditions, they generally need to be replaced after a certain age. For example, one source suggests that fuel injection lines are made to last anywhere from 50,000 to 75,000 miles. Another source mentions that fuel lines can last 30+ years, but it is recommended to replace them after 7-10 years as a preventative measure.
• Permeation: If the fuel lines are permeating, it could indicate that they are deteriorating and need to be replaced.
• Internal deterioration: Fuel lines that are showing signs of deterioration on the outside are likely to be deteriorated on the inside as well.
• Debris in the fuel filter or carb bowls: The presence of rubber debris could indicate that the fuel lines are breaking down and need to be replaced.

DIY vs. professional replacement

DIY vs. Professional Fuel Line Replacement

DIY

If you have a basic knowledge of car mechanics, you may be able to replace your fuel lines yourself. The first step is to empty the fuel line by removing the fuse for the fuel pump and starting the car. Once the fuel line is empty, you need to locate it and disconnect it at both ends. This can be tricky, as the fuel line disappears out of sight in some areas. Having a partner to shine a flashlight can be helpful. When removing the fuel line, be aware that it is locked in place by holders that are screwed or bolted on, and you may need a special solvent to remove the fittings. Insert the new fuel line in the same way as the old one, and remember to put the fuel pump fuse back in before starting the car again. Priming the new fuel line can be done by turning the car's ignition on and off a few times.

Professional

If you take your car to a professional, they will have the expertise to quickly and efficiently replace your fuel lines. They will also have access to pre-bent lines, which can be the longest-lasting repair option and prevent future leaks. Professionals will also be aware of safety standards and regulations, such as those set by the National Highway Traffic Safety Administration, which require fuel lines to be routed in a specific way to avoid the crumple zone in case of an accident. Additionally, professionals will have the necessary tools for the job, such as bending and flaring tools for creating custom fuel lines, as well as knowledge of which materials are suitable for your vehicle.

While it is possible to replace fuel lines yourself, there are advantages to having a professional do the job. Professionals can ensure the work is done safely and correctly, and they have access to the best tools and materials. They can also advise on the most suitable repair option for your vehicle, taking into account factors such as cost, labour, and longevity.

Safety precautions

Fuel systems, including fuel lines, pose several types of hazards, such as poisonousness, corrosive properties, and flammability. Gasoline, in particular, is highly flammable and can be ignited by even a tiny spark. Therefore, it is crucial to adhere to safety precautions when handling fuel and maintaining fuel systems. Here are some detailed safety measures to follow:

• Fire Prevention: Before performing any maintenance or repairs on a vehicle's fuel system, disconnect the negative battery cable unless the procedure specifically requires electrical power. This simple step helps prevent any accidental sparks that could ignite fuel vapors or sprays. Additionally, always keep a Class B fire extinguisher nearby. Unlike water, it contains dry chemicals that can effectively extinguish fuel fires by depriving them of oxygen.
• Protective Gear: When working on a vehicle with a high-pressure fuel system, it is crucial to prevent fuel from coming into contact with your skin, eyes, or mouth. Wear protective gear, such as gloves, goggles, and flame-resistant clothing. This gear, known as Personal Protective Equipment (PPE), provides essential safeguards against extreme hazards associated with fuels.
• Pressure Relief: Always relieve the pressure in the fuel lines before beginning any work on the fuel system. High-pressure fuel can penetrate your skin, leading to serious health risks.
• Spill and Leak Prevention: Absorb any leaking fuel immediately with shop towels or spill response kits. Wipe up spills, especially from engine surfaces, as they can become hot enough to ignite fuel. Always store fuel in approved containers that are sealed tightly to prevent leaks and spills.
• Safe Handling: Never use your mouth to start a siphon; instead, opt for a pump or hose. When loosening or tightening fuel-line fittings, use two wrenches to minimize stress on the fuel line.
• Work Area Safety: Plan and set up your work area with safety in mind. Ensure proper ventilation in fuel storage areas and have spill response kits and fire extinguishers easily accessible. Keep the fuel tank on a stable, low surface to reduce the risk of spills and accidents.
• Training and Protocols: Regular training for fuel-handling personnel is essential. Educate your staff about potential hazards and encourage them to promptly report any safety concerns. Establish well-defined protocols for responding to spills and other emergencies.
• Compliance and Regulations: Stay informed about regulatory requirements and adhere to fuel system safety standards established by authorities. This includes guidelines for storage, transportation, and spill response to protect both people and the environment.

Fuel line materials

Fuel lines are hoses or pipes that transfer fuel from one point in a vehicle to another. They are made from a variety of materials, each with its own advantages and disadvantages.

Metal Fuel Lines

Metal fuel lines are usually made from stainless steel, aluminium, or coated steel tubes. They are durable, resistant to wear and tear, and not prone to cracking or deterioration. Metal lines are also compatible with all types of fuel. However, they can be difficult to fabricate and are generally more expensive than other options. Metal fuel lines are typically found in most vehicles leaving the factory and hold up better than any soft material.

Rubber Fuel Lines

Rubber fuel lines are typically connected using barbed fittings and fuel line hose clamps. They are flexible, easy to install, and can be cut to the required length. However, they have some downsides. Rubber starts degrading as soon as it comes into contact with fuel and is susceptible to cuts, nicks, and other abrasions. Over time, rubber fuel lines can become hard and brittle, and they may not be suitable for use with certain fuels or chemicals.

Braided Fuel Lines

Braided fuel lines are made from a metal or synthetic fibre braid wrapped around a rubber or other elastomeric core. They are more durable than plain rubber lines and offer superior connections with AN hose fittings. However, they still have issues with long-term durability and fuel vapour leakage. Braided fuel lines are typically more flexible than metal lines but less flexible than rubber lines.

PTFE-Lined Fuel Lines

PTFE (polytetrafluoroethylene) lined fuel lines have an inner layer of synthetic fluoropolymer coated with a layer of braided stainless steel or other metal. They are highly durable, flexible, and resistant to wear, heat, and chemical damage. PTFE-lined hoses are the best soft hoses available and block fuel vapours while slowing the degradation process. However, they require special fittings and are generally more expensive than other types of fuel lines.

Nylon Tubing

Nylon tubing is a good option for fuel line repairs on a budget. It is more durable than plain rubber hose and can be used as an entire length of fuel line or just a section.

Copper Fuel Pipes

Older vehicles may have copper fuel pipes, which are easy to fit and repair. However, copper is heavy and expensive compared to other options.

Frequently asked questions