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1993 Corolla
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Discussion Starter #1
Hi folks. I replaced the fuel tank in my 1993 corolla because I thought it was the source of my fuel leak. It wasn't, but it had some rust holes in the top so it was due anyway. I noticed that my fuel lines are very crusty and the return line has a pretty serious leak, about 1 drop every 4 - 5 seconds. I put some JB Kwik Steel on it but it doesn't stick well because of the rapid rate of leakage. I was thinking of just getting a compression fitting and a short piece of metal line since it is so close to where it goes into the rubber line. My question is, does anyone know what size the line is? The guy at autozone seemed to think that it was 5/16" but that seemed a little big. My other thought was to just cut the line right before the leak and put some rubber hose on it and run it right up to the top of the tank, but I don't have any way of flaring it so I am not sure if it would stay on or not. I do have fuel line clamps but I am not sure if they would hold.
 

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1997 Corolla
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I've found that Gates hoses seems to fit the best. I think they make 1/4", 5/16" and 3/8" fuel return hose. 1/4" might be what you need. It's hit and miss whether local parts stores carry the bulk hoses that they cut to length. Around me O'Reilly and NAPA sometimes has it. One location may have it and another not.

Not sure about your other questions.
 

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1993 Corolla
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Discussion Starter #3
I'll check the local parts stores for 1/4". Does anyone know what size that return line is?
 

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1997 Corolla
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I'll check the local parts stores for 1/4". Does anyone know what size that return line is?
I would guess something metric, rather than the 5/8ths" the McParts store clerk suggested.

I think all McParts stores around here (Autozone, Advance, O'Reilly's, Pep Boy's, and NAPA) have spools of all different kinds of hose stock unless they recently disco'ed it, but they keep it in back and you have to ask. They'll often bring you back there to look at it, and that's a good time to match it up using your own eyes.
In today's world, it's extremely possible that you need to inform the clerk that they do indeed carry such items. The hoses might be near their bulk rolls of metal brake tubing stock that nobody knows they carry...
 

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1/4" = 6.35mm, so maybe the original rubber hoses were 6mm, but a lot of the 7th gens were built in the USA so maybe they went with standard sizes available. The outer texture on Gates hoses seems to match the texture on the original hoses (fuel, return, PS return, ATF oil cooler), so I speculate that they were the original supplier.
 

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Discussion Starter #6
The 5/16" seems loose enough on the barb going into the fuel sending unit that I think 1/4" would be a good snug fit.
 

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Discussion Starter #7
Well folks I am going to bring this one back up. I fixed my leaking return line but cutting about 10" of the line off and putting a bubble flare on and running 1/4" rubber line up to the tank. It works but even 1/4" seems a bit loose. Something hit my line and sliced the rubber line and I had to replace it again. It was a quick easy fix. I notices all of my lines are starting to "sweat" but not leaking. What I want to do is replace both return and the main feed line with nylon. They have metal to nylon fittings. Do you guys think 1/4" would work for the return lines and 3/8" for the feed? My plan was to cut the good metal ends off or flaring new metal ends and then converting them to nylon in the middle. Actually, my plan is to cut them off of a car at the junk yard and then replacing them from there. Any input would be helpful. I am planning on doing this in the spring and just dealing with the sweating lines since I don't have a garage and I wouldn't want to do the fuel lines inside anyway.
 

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You want as much metal line as possible, as you found out.

In my opinion, you're better off cutting up a good metal line to get it into the car, and then splicing it back together short lengths of fuel-rated hose and clamps. If doing that, you should flare ends of the metal line.
 

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What kind of hose (brand and type) did you use? The return line has no pressure, so it shouldn't be sweating. Maybe it's just condensation of water vapor from the lines being cooler than the outside air?
 

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Discussion Starter #10
I got whatever brand fuel hose that they sell at Advance auto. It looks like it actually tore. I have no concern with running Nylon line. My Chevy has almost all nylon line it and it has no issues. I think the line that is sweating is the main feed line. I just need to find out what size to buy before I rip it all out. I will see how much of the line I can get from the junkyard. Luckily the yard I go to pulls the tanks so that should save me a bunch of work.
 

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Discussion Starter #11
Just to note, they line that tore was rubber and not nylon. my return line rusted through so I just cut it and flared it and ran rubber line from there to the steel line that goes to the tank.
 

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Discussion Starter #12
So I went to the junk yard and they had a 1996 corolla there. I pulled the lines and they are actually in really good shape. They have a little bit of surface rust and some pitting where all 3 lines turn to go up towards the tank. I sanded the scale off and I think I will cover those areas with some steel stick just as some added protection. Either way I got a really decent set of lines for a couple hours of work and $6. I plan on throwing them in this weekend if the weather cooperates. I guess I lucked out.
 

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Maybe you could paint the outsides of the lines, or coat them somehow?
 

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Discussion Starter #15
Just for reference they feed line is 5/16" and the 2 vent/return lines are 1/4" I figured I would measure while I had it apart.
 

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Discussion Starter #16
Well, I got the lines in Saturday afternoon but of course it got dark by the time i was done. I started it and I got a drip.

Here is the old lines. I am not sure why my camera wouldn't quite focus
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Here is where the leak was coming from. The nylon line that comes down from the pump on the feed line kinked and got a tiny hole in it.
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Here is the joint I got to fix it.
https://www.amazon.com/gp/product/B000CIR1P2/ref=ppx_yo_dt_b_asin_title_o06_s00?ie=UTF8&psc=1
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And here it is installed. I just cut the steel line and the nylon line and spliced them together. These compression fittings work fantastic.
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I drove it around yesterday and drove to work today and no more leaks!
 

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Was just watching a video on youtube and watched a guy use one of those to patch a leaking airline which went to the PTO controls on a big truck. Apparently, those used to be considered a hack-ish repair, but they now come OEM on new trucks!
 

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Discussion Starter #18
Compression fittings are good for fuel lines because fuel lines don't really get as high pressure as air or brake lines. I would never use them for brakes.
 
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