Replacing Fuel Hoses

Fuel hoses rarely need to be changed, but if yours leaks or was damaged while changing a fuel filter, you'll need to make this repair.

NOTE: Because replacing a fuel hose can be quite dangerous, this is a fix better left to an experienced mechanic--this is not considered routine car maintenance.

Safety First

Since dealing with fuel lines could end in a giant fireball, follow all gasoline safety precautions. Don't smoke, make sure there's plenty of ventilation, and properly dispose of all gasoline-soaked rags, old parts, hoses, and any other items contaminated by gasoline. Keep a current and charged fire extinguisher handy, and do not forget to disconnect the vehicle's battery before you begin.

What You'll Need

It's important to use the correct tools for the job. Using the wrong tool, or using the right in the wrong way, may cause sparking. So make sure you've got correct tools before you start.

  • The service manual for your vehicle year, make, and model.
  • A dozen or so clean, dry shop rags to catch excess fuel.
  • Screwdriver or other tool as required to remove the hose clamps.
  • Pair of regular pliers.
  • Standard razor knife with blade-locking capability.
  • Fuel filter for you vehicle's make and model.

Don't worry if you if you can't figure out the diameter of the fuel line, because the auto parts store can look it up.

You must always replace the fuel filter on your vehicle if you will be changing the fuel hose.

Remove the Old Fuel Line

Once you have all your tools and new parts at the ready, you can begin the process of replacing your fuel hose.

  1. Locate the fuse box and remove the fuel pump fuse.
  2. Start the engine and run it until it stops.
  3. Remove the fuel filter and trace the fuel line to the transfer unit.
  4. Remove the air cleaner if you are changing the hose leading from the fuel filter to the carburetor.
  5. Put rags under the end of the hose where the gasoline will come out.
  6. Loosen the metal hose clamps just until the clamp slides back over the bump that is close to the end of the line.
  7. Place a rag over the end of the hose as you remove it from the filter.
  8. If the hose sticks and is difficult to remove, use the pliers to grip and turn the hose.
  9. If the hose still does not come away easily, use the razor knife to split the hose along the direction of the line.
  10. Have the shop rags ready, because the fuel in the line will begin to drain once the hose has been removed.
  11. Remove the fuel line from the steel tube at the fuel block. Twist it a bit if it is stuck.
  12. After you remove the hose, clean off any dirt, hardened rubber, fuel, or other contaminants from the steel tube.
  13. Place the old hose on your work bench to measure the new hose.

Attach the New Fuel Hose

Now that you've got the old hose removed, here's the steps you'll need to take:

  1. Place the still-loose clamps over the new fuel hose.
  2. Be sure the clamp screws face the correct direction for easy tightening.
  3. Check the new fuel filter to be sure it faces the correct fuel-flow direction.
  4. Place the hose ends on the steel tube and at the new fuel filter.
  5. Check the new fuel line for fit. If there are any kinks in the hose, remove the hose and trim a bit from the ends.
  6. Replace the clamps in the correct position and tighten the screws to hold them firmly in place.
  7. Reattach the hose to the new fuel filter, and then tighten the clamp.
  8. Reattach the vehicle's battery cables.
  9. Dispose of gasoline soaked rags, the old fuel line, and any contaminated items properly.

That's it! You've just replaced your fuel line. May you have excellent gas mileage, perfect performance, and a great ride.

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