Help! Gas fuel leak. Under driver's door. Fuel line to fuel rail connector.
Thread Starter
Banned
Joined: Oct 2012
Posts: 1,744
Likes: 2
From: USA
Year: 1998
Model: Cherokee
Engine: 4.0L i6
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.

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.
Last edited by BimmerJeeper; Oct 20, 2015 at 06:54 PM.
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Joined: Feb 2011
Posts: 14,479
Likes: 805
From: Blunt, South Dakota
Year: 97
Model: Cherokee (XJ)
Engine: 4.6 stroker
The ones I use look like this

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.

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.
Thread Starter
Banned
Joined: Oct 2012
Posts: 1,744
Likes: 2
From: USA
Year: 1998
Model: Cherokee
Engine: 4.0L i6
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...
Does this seem like a reasonable plan?
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...
Does this seem like a reasonable plan?
Last edited by BimmerJeeper; Oct 18, 2015 at 08:11 PM.
::CF Administrator::





Joined: Feb 2011
Posts: 14,479
Likes: 805
From: Blunt, South Dakota
Year: 97
Model: Cherokee (XJ)
Engine: 4.6 stroker
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?
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?
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?

LOL
Last edited by Rogue4x4; Oct 18, 2015 at 08:22 PM.
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Thread Starter
Banned
Joined: Oct 2012
Posts: 1,744
Likes: 2
From: USA
Year: 1998
Model: Cherokee
Engine: 4.0L i6
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.
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.
::CF Administrator::





Joined: Feb 2011
Posts: 14,479
Likes: 805
From: Blunt, South Dakota
Year: 97
Model: Cherokee (XJ)
Engine: 4.6 stroker
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.
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.
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.
Thread Starter
Banned
Joined: Oct 2012
Posts: 1,744
Likes: 2
From: USA
Year: 1998
Model: Cherokee
Engine: 4.0L i6
Thank you. I will report back in a few days.
The big question is if I can just splice this onto the rubber line
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.
Thread Starter
Banned
Joined: Oct 2012
Posts: 1,744
Likes: 2
From: USA
Year: 1998
Model: Cherokee
Engine: 4.0L i6
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.
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.


