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Help! Gas fuel leak. Under driver's door. Fuel line to fuel rail connector.

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Old Oct 18, 2015 | 06:45 PM
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Default Solved! Gas fuel leak. Under driver's door. Fuel line to fuel rail connector.

This is a steady drip. Made a small pool within a few minutes.


This thread was helpful.
I bought the same quick disconnect fitting and hose clamps.
https://www.cherokeeforum.com/f51/le...nt-fix-170244/

One error in the link above. He removes the plastic release tab for no reason.
It is there so you don't need the weird disconnect tools to release it. So, just leave it on.

First, I tried to only swap the quick disconnect fitting from the hose, but it was rusted solid onto the hose.
But, I did not replace the entire line to the fuel rail. Not needed.
There is an 8" length of hose that reconnects to a hard line that goes up to the fuel rail.
So, I sliced that short hose open (on the other end of the quick disconnect) to detach it from the hard line
I simply replaced that section with 5/16" fuel injection hose and my new fitting


I am also going to replace the quick disconnect on the other end of the line, right at the fuel rail.
It has an o-ring that may go bad, plus mine is also rusty. $7 and 60 seconds to replace.
Amazon.com: Dorman 800-120 Fuel Connector: Automotive Amazon.com: Dorman 800-120 Fuel Connector: Automotive


Last edited by BimmerJeeper; Oct 20, 2015 at 06:54 PM.
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Old Oct 18, 2015 | 07:15 PM
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Do you think I will be able to disconnect the rusty quik disconnect?
Or will it be stuck solid ?
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Old Oct 18, 2015 | 07:16 PM
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Replace the entire line.
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Old Oct 18, 2015 | 07:26 PM
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Which quick disconnect tool do I need?

Last edited by BimmerJeeper; Oct 18, 2015 at 07:28 PM.
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Old Oct 18, 2015 | 08:04 PM
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The ones I use look like this

Name:  fuel line disconnect tool.jpg
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Around $20 for a set, and you can get them individually for about $4-5...I believe it is a 5/16"...verify that first though, not 100% on that...

Seriously consider replacing the entire line from the fuel rail to the gas tank...I'm willing to bet that isn't the only spot that's corroded.

Last edited by Rogue4x4; Oct 18, 2015 at 08:06 PM.
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Old Oct 18, 2015 | 08:07 PM
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Thanks. It looks like 5/16" from other threads.

I now understand how the disconnect tools works.
I guess the spring loaded ones or the scissor one works better.

I think the leak is probably from the rusted quick connector and maybe the o-ring,
and not the hard fuel line itself.

I think I am going to order this and try to hose clamp it on...
Amazon.com: Dorman 800-120 Fuel Connector: Automotive Amazon.com: Dorman 800-120 Fuel Connector: Automotive

Does this seem like a reasonable plan?

Last edited by BimmerJeeper; Oct 18, 2015 at 08:11 PM.
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Old Oct 18, 2015 | 08:19 PM
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Originally Posted by BimmerJeeper
Thanks. It looks like 5/16" from other threads.

I now understand how the disconnect tools works.
I guess the spring loaded ones or the scissor one works better.

I think the leak is probably from the rusted quick connector and maybe the o-ring,
and not the hard fuel line itself.

I think I am going to order this and try to hose clamp it on...
Amazon.com: Dorman 800-120 Fuel Connector: Automotive

Does this seem like a reasonable plan?
The type of tool used depends on the make and model of the car. The scissors type and spring loaded ones may or may not work. Get a set that works with Chrysler/GM vehicles.

It may work. I would just replace the entire line if it were me. You have a lot of corrosion. Your leak is manifesting at a disconnect, yes, but I would replace the entire line, just because of the history of your vehicle. Otherwise, you'll be doing this all again in the near future. And, it's a fuel line...you don't want your jeep to go from under the sea to this do you?
Name:  burning jeep.jpg
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LOL

Last edited by Rogue4x4; Oct 18, 2015 at 08:22 PM.
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Old Oct 18, 2015 | 08:25 PM
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I feel you. But the fuel line is rubber. Take a look at the photo again. The hard line is perfectly clean, and the other side is rubber. I actually think it will be safer to just replace the Quick Disconnect coupler.

The question is, how do I remove the rusty disconnect? I'm not even sure I see a clamp in the photo. Not sure I can just cut off the length, in case there isn't enough slack in the rubber hose. I will look again at the car in the morning.
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Old Oct 18, 2015 | 08:31 PM
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Originally Posted by BimmerJeeper
I feel you. But the fuel line is rubber. Take a look at the photo again. The hard line is perfectly clean, and the other side is rubber. I actually think it will be safer to just replace the Quick Disconnect coupler.

The question is, how do I remove the rusty disconnect? I'm not even sure I see a clamp in the photo. Not sure I can just cut off the length, in case there isn't enough slack in the rubber hose. I will look again at the car in the morning.
Do yourself a favor and inspect the ENTIRE fuel line before making a decision. An ounce of prevention is worth a pound of cure.

Spray the disconnect with a penetrant spray, and use a wire brush to remove as much corrosion as you can. Then try the disconnect tool. Remember to relieve the pressure in the fuel line first.
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Old Oct 18, 2015 | 08:33 PM
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Thank you. I will report back in a few days.
The big question is if I can just splice this onto the rubber line

Last edited by BimmerJeeper; Oct 18, 2015 at 08:44 PM.
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Old Oct 18, 2015 | 08:35 PM
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Good luck.
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Old Oct 20, 2015 | 06:53 PM
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Got it done.
Thanks ronin for the help.

I bought the same quick disconnect fitting and hose clamps.
https://www.cherokeeforum.com/f51/le...nt-fix-170244/

One error in the link above. He removes the plastic release tab for no reason.
It is there so you don't need the weird disconnect tools to release it. So, just leave it on.

First, I tried to only swap the quick disconnect fitting from the hose, but it was rusted solid onto the hose.
But, I did not replace the entire line to the fuel rail. Not needed.
There is an 8" length of hose that reconnects to a hard line that goes up to the fuel rail.
So, I sliced that short hose open (on the other end of the quick disconnect) to detach it from the hard line
I simply replaced that section with 5/16" fuel injection hose and my new fitting


I am also going to replace the quick disconnect on the other end of the line, right at the fuel rail.
It has an o-ring that may go bad, plus mine is also rusty. $7 and 60 seconds to replace.
Amazon.com: Dorman 800-120 Fuel Connector: Automotive Amazon.com: Dorman 800-120 Fuel Connector: Automotive

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Old Oct 20, 2015 | 07:03 PM
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Glad to be of service. Good job.
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Old Oct 20, 2015 | 07:04 PM
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U ever finish your rocker repair yet?
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Old Oct 20, 2015 | 07:16 PM
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Originally Posted by XJwonders
U ever finish your rocker repair yet?
No, the thread was deleted, so I never was able to learn how to do it
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