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Fuel Line Coupler: Service and Repair

Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type, a plastic retainer ring type or a latch clip type. Certain fittings may require the use of a special tool for disconnection.

SINGLE-TAB TYPE

Single-Tab Type Fitting:




This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component.

CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or fuel lines tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

Disconnection/Connection
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.

Disconnecting Single-tab Type Fitting:




4. Press release tab on side of fitting to release pull tab.

CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be damaged.

5. While pressing release tab on side of fitting, use a screwdriver to pry up pull tab.

Removing Pull Tab:




6. Raise pull tab until it separates from quick-connect fitting. Discard old pull tab.
7. Disconnect quick-connect fitting from fuel system component being serviced.
8. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary.
9. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
10. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting.
11. Obtain a new pull tab. Push new tab down until it locks into place in quick-connect fitting.
12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
13. Connect negative cable to battery.
14. Start engine and check for leaks.

Typical Two-Tab Type Quick-connect Fitting:




TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced.

CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE.

Disconnection/Connection
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.
4. To disconnect quick-connect fitting, squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick- connect fitting connector body.
5. Inspect quick-connect fitting body and component for damage. Replace as necessary.

CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage.

6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard.
8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
9. Connect negative cable to battery.
10. Start engine and check for leaks.

Plastic Retainer Ring Type Fitting:




PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color.

CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

Disconnection/Connection
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
2. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.
4. To release fuel system component from quick- connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection.
5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body.
6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary.
7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
8. Insert quick-connect fitting into component being serviced until a click is felt.
9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
10. Connect negative battery cable to battery.
11. Start engine and check for leaks.

Latch Clip Removal:




LATCH CLIP FITTING (FUEL LINE-TO-FUEL RAIL)
A tethered latch clip is used to secure the fuel line to the fuel rail. A special tool will be necessary to separate fuel line from fuel rail after latch clip is removed. This same latch clip may also be used to secure other different fuel system components.

CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

Disconnection/Connection
1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.
1. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.
4. Pry up on latch clip with a screwdriver.
5. Slide latch clip toward fuel rail while lifting with screwdriver.

Fuel Line Disconnection:




6. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line. Use this tool to release locking fingers in end of line.
7. With special tool still inserted, pull fuel line from fuel rail.
8. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line.
9. Prior to connecting fuel line to fuel rail, check condition of both fittings. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
10. Insert fuel line onto fuel rail until a click is felt.
11. Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail. Recheck fuel line connection.
12. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.).
13. Connect negative battery cable to battery.
14. Start engine and check for leaks.

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