So, my XJ has been suffering from a fuel leak where the rubber tank-to-filter line meets the fuel pump on the tank.


First, get some tools and parts together.  A couple screwdrivers, some zip ties, a source of light, and a utility knife.

As for parts, I like to buy American so with a little searching I got some high pressure rubber line that's 3/8" ID (four feet) and some hose clamps all made here on the home front.


And here's a look at the belly of the Jeep we'll be working on.  Note rusty hose clamp.


Here's the other end of the fuel line, the fuel filter.  I used a short length to connect the filter to hard line as I had to cut the old rubber line since that clamp was totally gone.  The little stub wasn't long enough and resulted in leaks.  The new one I cut was longer than needed, but works well.


After effort and magic words failed to help, I ended up reaching for the dremel tool.  Some careful cutting removed the clamp without cutting through the line and therefore letting fumes out around a running power tool.  That would not be safe!


Well, after pulling the old rubber line off, I'm not attaching the new line to this.  Time for a new fuel pump.  It works well, but the corossion is pretty bad on it, especially on the nipple where the fuel hose connects.

...another pic of the same...


From here I stuck the old fuel line on the broken/corroded nipple, to prevent fuel contamination.  Well, now I'm waiting for a fuel pump.  Updates to come.

-- Edited by ChevelleSSLS6 at 13:59, 2009-01-07