Upper/Front Fuel Line Cracked
 

I figured this would be helpful to anyone with a mysterious fuel odor.

The fuel line that connects to the fuel rail ends just under the firewall, with a connector. It's stainless steel, so you wouldn't suspect that it would rust out and leak.

However, as I learned just recently with my XJ, they CAN crack.

The only secure mounting point for that part of the line is a little bracket that holds it to the intake manifold. Because the line can flex and move on either end of that bracket, any sort of extreme movement could crack it, if the conditions are right.

After doing my injector swap, I noticed a fuel smell. I didn't see anything dripping (it was apparently evaporating on the exhaust), but when I took off that little clamp/bracket, there was a very fine mist spraying from it.

I think it might be hard to diagnose for some, since you just wouldn't expect a stainless steel fuel line to crack like that...

Since it's Stainless Steel, it's very difficult to flare, so despite cutting out the small cracked section I still couldn't use connectors to make the line whole again.

I ended up just buying a replacement line, which ran a decent $50 from Napa.

VERY simple repair, you just unclip it from the fuel rail, unclip it where it connects down below the firewall, unclip it from the little plastic holder piece on the firewall, and take out the little bolt that holds it against the manifold.

Be sure to release the fuel pressure first, of course.

The new one just slips back into place and connects. The only tool you need is a fuel line disconnect tool and a socket (I think it was a 10mm) for the bolt.

It's easily a 5 minute job.

If anyone else has a mysterious fuel leak, take a look at that spot where the fuel line is held to the intake manifold.