Fuel Line Coupler: Service and Repair
Hair Pin Clip:
Hairpin Clip Fittings
Removal
NOTE: If necessary, drain fuel tank: Service and Repair
1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly.
NOTE: On 90-degree elbow connectors, excessive side loading could break the connector body.
2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube.
CAUTION: Do not use any tools. The use of tools may cause a deformity in clip components which may cause fuel leaks.
3. Remove hairpin-type clip from fitting by first bending the shipping tab downward so that it will clear the body. Next (USING HANDS ONLY) spread the two clip legs about 3.2 mm (1/8 inch) each to disengage the body and push the legs into the fitting. Complete removal is accomplished by LIGHTLY pulling from the triangular end of the clip and working it clear of the tube and fitting.
4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube.
5. When fitting is removed from the tube end, inspect the fitting and tube for any internal parts that may have been dislodged from the fitting. Any loose internal parts should be immediately installed, using the mating tube to insert the parts.
Installation
1. It is recommended that the original clip NOT be reused in the fitting. To install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs of hairpin clip locked on outside of body). Piloting with an index finger is necessary.
2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to make sure it is free of dirt and/or obstructions.
3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged, a definite "click" will be heard. Pull on fitting to make sure it is fully engaged. Applying a light coat of oil to the tube end will aid assembly.
Duck Bill Clip Fittings
Removal
One of the two following methods is to be followed to disconnect the fitting:
^ If necessary, drain fuel tank: Service and Repair
^ Before attempting to disconnect the fitting, inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly.
^ Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube.
Method One
1. To disengage the tube from the fitting, align the slot on Quick Connect/Disconnect Tool T82L-9500-AH or equivalent with either tab on the clip (90 degrees from the slots on side of fitting) and insert the tool. This disengages the duck bill from the tube.
NOTE: Only moderate effort is required if the tube has been properly disengaged. Use hands only.
2. Holding the tool and the tube with one hand, pull fitting away from the tube.
NOTE: Some fuel tubes have a secondary bead which aligns with the outer surface of the clip. These beads can make tool insertion difficult. If there is extreme difficulty, use the disassembly method described below.
3. After disassembly, inspect and clean the tube sealing surface. Also inspect the inside of the fitting and the tube for any internal parts that may have been dislodged from the fitting. Any loose internal parts should be immediately installed using the mating tube to insert the parts.
Method Two
This method of disassembly disengages the retaining clip from the fitting body.
Use with a pair of narrow pliers; 152 mm (6 inches) channel lock pliers are ideal. The pliers must have a jaw width of 5 mm (0.2 inch) or less.
1. Align the jaws of the pliers with the openings in the side of the fitting case and compress the portion of the retaining clip that engages the fitting case. This disengages the retaining clip from the case (often one side of the clip will disengage before the other; it is necessary to disengage the clip from both openings).
NOTE: Only moderate effort is required if the retaining clip has been properly disengaged. Use hands only.
2. Pull the fitting off the tube.
3. When fitting is removed from the tube end, inspect the fitting and tube for any internal parts that may have been dislodged from the fitting. Any loose internal parts should be immediately installed, using the mating tube to insert the parts.
4. The retaining clip will remain on the tube. Disengage the clip from the tube bead and remove.
Installation
1. It is recommended that the retaining clip NOT be reused. Install the new replacement clip into the body by inserting one of the retaining clip serrated edges on the duck-bill portion into one of the window openings. Push on the other side until the clip snaps into place.
2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to make sure it is free of dirt and / or obstructions.
3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged, a definite "click" will be heard. Pull on fitting to make sure it is fully engaged. Applying a light coat of clean engine oil to the tube end will ease assembly.
Spring Lock Couplings
WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE TO PREVENT POSSIBLE INJURY. REFER TO FUEL PRESSURE RELIEF.
WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
Fuel Tube Clip:
Removal
1. Remove redundant clip from spring lock coupling.
2. Position Spring Lock Coupling Disconnect Tool D87L-9280-A or equivalent for 3/8 inch tube or D87L-9280-B or equivalent for 1/2 inch tube onto coupling. Make sure that tool can enter cage opening to release the garter spring.
3. Push the spring lock coupling disconnect tool into the cage opening to release the female fitting from the garter spring.
4. Pull the coupling male and female fittings apart.
5. Remove the tool from the disconnected coupling.
NOTE: Inspect coupling for missing or damaged 0-rings. If either O-ring is damaged, both O-rings must be replaced. Replace 0-rings or garter springs with the appropriate replacement parts only.
6. Clean fittings with solvent.
Installation
1. Lubricate the 0-rings with clean engine oil.
2. Insert male fitting into female fitting and push together until garter spring is engaged.
3. Pull on fittings to make sure of coupling engagement.
4. Install redundant clip to spring lock coupling.
5. Make sure clip is correctly installed.