Screwed up bad (I think)

[sabbathman]

So my 97 4.0 has not been started for 10 years. I'm not familiar with fuel injection either. I added gas to the tank as it was empty.

Jeep cranked but wouldn't start. I decided to see if gas was actually getting to the rail. I thought the fuel line would be like what you'd have at a carb...I mean I saw what appeared to be black rubber fuel hose, (similar to the rubber fuel hose connected on a carb), connected to some sort of a steel fuel line fitting at the rail.

But then I noticed instead of a steel house clamp there was this funny looking black plastic clamp with a set of teeth that wasn't very tight on the black fuel hose?

I wasn't quite sure what to make of that but OK, I'll disconnect the plastic hose clamp then slide the black hose off and away from the steel line attached to the fuel rail. What I then thought was I should be able to see some fuel in the black hose, right? Wrong.

What I ended up discovering was...what I thought was black rubber fuel hose was actually a rubber hose covering what looks like black heat shrink tubing that attaches the steel fuel line to the fuel rail.

My issue is that I've cut that heat shrink tubing part and now gas is squirting out when ever I turn the ignition on.

I know it's the fuel pump building up pressure when the ignition is on which is causing the fuel to squirt out that rubber or plastic heat shrink tubing part.

What do I need to buy to fix what I've done? Any help is appreciated. Also I know I'm not saying the correct terminology either so some direction with what these parts are called would be helpful too.

Thanks much.

 

[MichaelGH]

Check with Davey’s Jeeps in Salem, Ohio.
They tend to have take-off lines and such.
I have purchased from them many times over.

 

[macleanflood]

Someone said Davey's Jeep was out of business...I don't know.

There's DeadJeeps.com and people are always parting them out.

You could make one with QD adapters to AN lines...but extra fittings equals more places to leak.

I wrote this up for the rear one...we ought to figure out how to make a new front one.

Thread 'Rear Fuel Line: How to Make a New Plastic Nylon Line'

Aug 31, 2025

So after my track bar came up like a guillotine and severed my plastic fuel line that runs from the tank to the hard line attached to the chassis I went on quite a journey making a replacement.

Here's the parts you need:

3/8s to 5/16 barbed QD fitting:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 barbed QD fitting:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16" nylon fuel line:

https://www.amazon.com/your-orders/pop?tag=wranglerorg-20

I haven't ID a good sleeve material...OEM has a foam line...

• macleanflood
• Replies: 1
• Forum: TJ Resources

• 

-Mac

 

[MichaelGH]

I just talked to them via email recently.
They were still there.
Hopefully they stay open.

 

[sabbathman]

Check with Davey’s Jeeps in Salem, Ohio.
They tend to have take-off lines and such.
I have purchased from them many times over.

Awww darn it! I was trying to stay on a little too no cost in getting the 97 back on the road... guess I screwed that idea. Thanks for the info I'll give these guys a shout.

 

[sabbathman]

Someone said Davey's Jeep was out of business...I don't know.

There's DeadJeeps.com and people are always parting them out.

You could make one with QD adapters to AN lines...but extra fittings equals more places to leak.

I wrote this up for the rear one...we ought to figure out how to make a new front one.

Thread 'Rear Fuel Line: How to Make a New Plastic Nylon Line'

Aug 31, 2025

So after my track bar came up like a guillotine and severed my plastic fuel line that runs from the tank to the hard line attached to the chassis I went on quite a journey making a replacement.

Here's the parts you need:

3/8s to 5/16 barbed QD fitting:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 barbed QD fitting:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16" nylon fuel line:

https://www.amazon.com/your-orders/pop?tag=wranglerorg-20

I haven't ID a good sleeve material...OEM has a foam line...

• macleanflood
• Replies: 1
• Forum: TJ Resources

• 

-Mac

Someone said Davey's Jeep was out of business...I don't know.

There's DeadJeeps.com and people are always parting them out.

You could make one with QD adapters to AN lines...but extra fittings equals more places to leak.

I wrote this up for the rear one...we ought to figure out how to make a new front one.

Thread 'Rear Fuel Line: How to Make a New Plastic Nylon Line'

Aug 31, 2025

So after my track bar came up like a guillotine and severed my plastic fuel line that runs from the tank to the hard line attached to the chassis I went on quite a journey making a replacement.

Here's the parts you need:

3/8s to 5/16 barbed QD fitting:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 barbed QD fitting:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16" nylon fuel line:

https://www.amazon.com/your-orders/pop?tag=wranglerorg-20

I haven't ID a good sleeve material...OEM has a foam line...

• macleanflood
• Replies: 1
• Forum: TJ Resources

• 

-Mac

Hmmmmm this is a good idea... never even thought about it really. I'll look into it. Thanks

 

[jeepguy03]

Yeah you likely cut through the fuel line. You should be able to find used ones on ebay also.

I would HIGHLY recommend purchasing a factory service manual or even just a Chilton or Haynes repair manual. You can cause a lot of damage and unnecessary repairs if you don't know what you are doing.

 

[Obi-Wan]

@sabbathman , we have the FSM (Factory Service Manuals) available for free download right HERE.

 

[sabbathman]

Yeah you likely cut through the fuel line. You should be able to find used ones on ebay also.

I would HIGHLY recommend purchasing a factory service manual or even just a Chilton or Haynes repair manual. You can cause a lot of damage and unnecessary repairs if you don't know what you are doing.

Good idea... thanks much.

 

[NskLJ]

So my 97 4.0 has not been started for 10 years. I'm not familiar with fuel injection either. I added gas to the tank as it was empty.

Jeep cranked but wouldn't start. I decided to see if gas was actually getting to the rail. I thought the fuel line would be like what you'd have at a carb...I mean I saw what appeared to be black rubber fuel hose, (similar to the rubber fuel hose connected on a carb), connected to some sort of a steel fuel line fitting at the rail.

But then I noticed instead of a steel house clamp there was this funny looking black plastic clamp with a set of teeth that wasn't very tight on the black fuel hose?

I wasn't quite sure what to make of that but OK, I'll disconnect the plastic hose clamp then slide the black hose off and away from the steel line attached to the fuel rail. What I then thought was I should be able to see some fuel in the black hose, right? Wrong.

What I ended up discovering was...what I thought was black rubber fuel hose was actually a rubber hose covering what looks like black heat shrink tubing that attaches the steel fuel line to the fuel rail.

My issue is that I've cut that heat shrink tubing part and now gas is squirting out when ever I turn the ignition on.

I know it's the fuel pump building up pressure when the ignition is on which is causing the fuel to squirt out that rubber or plastic heat shrink tubing part.

What do I need to buy to fix what I've done? Any help is appreciated. Also I know I'm not saying the correct terminology either so some direction with what these parts are called would be helpful too.

Thanks much.

Not sure where this connects to under the vehicle, might be worth a look
https://www.extremeterrain.com/russ..._Im2e-kiWl_GnnKdfJ8nvZ9OnlJnDFPwaAjqbEALw_wcB

 

[sabbathman]

Not sure where this connects to under the vehicle, might be worth a look
https://www.extremeterrain.com/russell-jeep-wrangler-stainless-steel-braided-fuel-line-651111.html?utm_content=XTEngineandPerformance-Other|Russell&T5_Var4=J215998&utm_campaign=XTW+Wrangler+Brands+&+Vehicle+Low+LTVMiddle&dialogtech=ppc&utm_source=google-pla&utm_medium=shopping&T5_Var2=shopping&gclsrc=aw.ds&gad_source=1&gad_campaignid=22708856819&gbraid=0AAAAADdHURRpbrfC9MRLBJZgaZgj7S_tq&gclid=Cj0KCQjw5onGBhDeARIsAFK6QJbNER0Rr094M3si0PcxOjR_Im2e-kiWl_GnnKdfJ8nvZ9OnlJnDFPwaAjqbEALw_wcB

Yes this looks like it might be a viable solution... thanks much.

 

[macleanflood]

That's the rear fuel line. Not the front.

-Mac

 

[NskLJ]

Yes this looks like it might be a viable solution... thanks much.

Summit racing has the same part

 

[ChasUGC]

Awww darn it! I was trying to stay on a little too no cost in getting the 97 back on the road

That probably explains the first part.

So my 97 4.0 has not been started for 10 years. I'm not familiar with fuel injection either.

It might be time to rethink goals and objectives.

 

[lBasket]

That probably explains the first part.

It might be time to rethink goals and objectives.

Or reconsider the knife being option #1 at least

 

[NskLJ]

That's the rear fuel line. Not the front.

-Mac

Mac, is that from the tank to the frame rail? It was not clear in any of the descriptions. One way to fix it would be flair the metal tube and use some fuel injection hose with barbed fittings and the correct clamps?