Problems replacing fuel filter - Toyota Nation Forum : Toyota Car and Truck Forums

daw22 · 10-02-2011, 02:53 PM

In an effort to be good to my car (1996 Avalon), I decided to replace the fuel filter. There's a very good DIY on how to do it :
http://hardlymoving.hubpages.com/hub...-Body-Cleaning
I noticed that the lower fuel line fitting was a little rounded off, but I figured that with my 14mm crowfoot flare nut wrench it wouldn't be a problem. I hit it with PB blaster several times as well. Well, it started to come off, about 1/2 turn would be my guess, then it just froze. Now I can't turn it any further out without rounding over the fitting and I can't get it to go back in without rounding. So, now I don't have a seal at the bottom of the filter. I can't drive it of course. So, any suggestions? The metal line (8mm) that attaches to the bottom of the filter runs all the way to the front of the gas tank, where there is a fitting as it joins a nylon fuel line that seems to be heading to the top of the tank. That fitting looks very corroded and I'd bet anything that any attempt to undo it will be met with more problems. Then I'd be looking at having to drop the tank and replace all the lines. One thought I had would be to splice it a new piece of metal or nylon line from somewhere just a short ways away from the filter and run that up into a new filter. However, I have no idea where I'd get the fittings, particularly one that would fit into the bottom of the filter. I'd appreciate any help.

daw22 · 10-02-2011, 03:05 PM

I kit like this

Amazon

looks like it would be the right idea, but I'm not sure if it would have the right size fittings

hawkeye · 10-02-2011, 03:23 PM

Had this problem a couple years ago after I twisted my fuel line trying to remove it, very common in Camrys. My solution was to go to the Boneyard, find a car like mine with a fuel line end that could be removed from the filter. Using a pipe cutter, I severed it about 6" from the end where the line is straight. Cut mine in the same location then spliced the salvaged end onto my fuel line with 1/4" rubber fuel line and hose clamps.

May not be the most elegant solution, but it has never given me any problems since.

daw22 · 10-02-2011, 03:54 PM

I've done a little further research. I measured the inlet on the fuel filter and it's 14mm with 1.5 threads. It looks like this is a pretty common fitting size. It also seems that people use 5/16" and 8mm line pretty interchangeably (5/16" = .793mm). This part looks pretty good:

http://www.oreillyauto.com/site/c/de...1650&ppt=C0290

It's a 30" piece of 5/16" with a 14mm fitting at one end and a line to line splicer to connect it to the old line for $25. Tubing benders can be had for $8 on line. There may be hope yet.

carsrus · 10-02-2011, 08:30 PM

You might wanna hit up your local auto parts place before ordering that. Its a common thing to use a compression fitting and a chunk of line to fix this. Its not ideal but it work.

daw22 · 10-12-2011, 06:37 AM

I figured I'd give an update on fixing the fuel line. The fuel line is attached to the bottom of the filter with a 14mm fitting. However, the pre made lines with fittings attached that I looked at (for example from Dorman) wouldn't work. The end of the fuel line on those is the wrong shape. What you need to do is get a flaring kit. As the name suggests, this puts a flare on the end of the line that will allow a perfect seal. I got a new piece of 5/16 (8mm) steel line and a new M14-1.5 fuel line fitting for 5/16" line. I needed a 90 degree bend on the line so it would line up with the cut I had made in the existing line. I made the cut with a small plumbing pipe cutter. To make the bend, a tubing bender would be the best. I didn't have one however. So, I cut a piece of wood 5/16" thick with the exact curve I wanted. I clamped pieces of metal on either side of it to create a channel for the fuel line to follow as I bent it to prevent kinking. It worked. To attach the old line to the new line, I used 5/16" ID rubber fuel line with 2 hose clamps on each side. The 2 ends of the fuel line I was joining with the hose were only about 1/16" apart. A compression fitting to attach the 2 lines would be another way to attach them, but I figured this would work based on hawkeye's post.

toovira · 10-12-2011, 06:57 AM

Pre-fab lines (similar to brake line) - cutback the original line using Dremel or die-grinder (non-crushing cut), debur, and use Double flaring tool from Harbor Freight for $20. Then put a union join attaching the pre-fab line to the old line. Do not over-torque (follow spec). B-nut type fitting do not require much torque (brake lines are only 10 ft-lbs).