Fuel Line Coupler: Service and Repair

Fuel Line/Quick-Connect Fittings Precaution

The fuel tube/quick-connect fittings assembly connects the in-tank fuel pump to the fuel feed line and the fuel return line. When removing or installing the fuel tank unit and fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following:
- The fuel lines (A) and quick-connect fittings (B) are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures.
- The fuel lines (A) and quick-connect fittings (B) are not acid-proof; do not touch them with a shop towel which was used for wiping battery electrolyte. Replace them if they came into contact with electrolyte or something similar.







- When connecting or disconnecting the fuel lines (A) and quick-connect fittings (B), be careful not to bend or twist them excessively. Replace them if damaged.




A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line.
Replace the retainer when
- replacing the fuel pump.
- replacing the fuel filter.
- replacing the fuel feed line.
- replacing the fuel return line.
- it has been removed from the line.
- it is damaged.

Fuel Line/Quick-Connect Fittings Removal

1. Relieve fuel pressure.
2. Check the fuel quick-connect fittings for dirt, and clean if necessary.





3. Hold the connector (A) with one hand and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.

NOTE:
- Be careful not to damage the line (D) or other parts.
Do not use tools.
- If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
- Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.





4. Check the contact area (A) of the line (B) for dirt and damage.
- If the surface is dirty, clean it.
- If the surface is rusty or damaged, replace the fuel pump, fuel filter, fuel feed line, or fuel return line.





5. To prevent damage and keep foreign matter out, cover the disconnected connector and line end with plastic bags (A).

NOTE:
- The retainer cannot be reused once it has been removed from the line.
Replace the retainer when
- replacing the fuel pump.
- replacing the fuel filter.
- replacing the fuel feed line.
- replacing the fuel return line.
- it has been removed from the line.
- it is damaged.

Fuel Line/Quick-Connect Fittings Installation





1. Check the contact area (A) of the line (B) for dirt and damage, and clean if necessary.





2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after
- replacing the fuel pump.
- replacing the fuel filter.
- replacing the fuel feed line.
- replacing the fuel return line.
- removing the retainer from the line.





3. Before connecting a new fuel line/quick-connect fitting assembly (A), remove the old retainer from the mating line.





4. Align the quick-connect fittings with the line (A), and align the retainer (B) locking pawls with the connector (C) grooves. Then press the quick-connect fittings onto the line until both retainer tabs lock with a clicking sound.

NOTE: If it is hard to connect, put a small amount of new engine oil on the line end.





5. Make sure the connection is secure and that the tabs are firmly locked into place; check visually and by pulling the connector.
6. Reconnect the battery' negative cable, and turn the ignition switch ON (II). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system.