'97 Fuel line leak near tank

[Gunn]

I have a 1997 Chevrolet K1500 extended cab 4WD with 5.0L engine that has developed a pretty nasty fuel leak pretty quickly. I gave it a good look tonight and found that it is coming from a steel to rubber connector that is right near the fuel tank under the driver side door area.

See my couple of photos of the problem area at: http://home.earthlink.net/~tomsbarn/fuel_line.html..... (Click on the photos for 1024x768 views).

Looks like a steel line is coming out of the top of the tank somewhere...then it transfers into a rubber line with some sort of special crimped on fitting. It is right here where it is leaking. The line stays rubber for a few inches, then has what looks like to be a similiar connector that transfers back to steel for the line going up front. This small length of rubber hose must be to remove the vibrations or something...

Anyway, the fitting that can be easily seen is major corroded. I'm assuming the other where the leak is coming from is the same...hard to get a good look.

My question is this: If I remove the tank to replace this, how do I go about replacing this section and these connectors? Do I just substitute it for standard fuel line and hose clamps? Or do I have to get some specialized tool to crimp it on???

Looks like I have to remove the tank just to get to this line...its really jammed up in there. Looks fairly easy...is it?!

Thanks!

[GMMerlin]

The lines are available from GM.
I replace the lines as necessary instead of repairing them (liability issues for me)
The lines follow the frame rail and are fairly easy to replace.

[BOOZER]

The only downfall is there darn expensive for what they are. But if you want it done wright, replace them, remember you have pressurized fuel.

[Gunn]

Thanks for the info. Intead of taking off the tank, I'm about ready to just remove the bed and get to it topside. It's ready to come off...just have to get a couple friends over tomorrow to lift it off.

I assume the dealer will have this crimping type tool so I can replace this small line? Or can I save a few $$ and get it at an auto parts store? If so, what's it called and what's it look like?

Thanks again,

[BOOZER]

The feed or the return line are serviced as assy's.
At the tank/sender you have a fitting on a flex hose
& a hard line after that, it's an assembly.The feed line will run from the sender to the filter, the larger of the two.The return is the smaller, right along side it.
The lines are not repairable, remember its pressurised fuel, a proper repair is to replace them.
If you hack it make sure your insurance is up to date.
The last time I checked the lines ran somewhere around $60.00-$80.00 each, I said they wern't cheap!

[GMMerlin]

Originally Posted by Gunn

Thanks for the info. Intead of taking off the tank, I'm about ready to just remove the bed and get to it topside. It's ready to come off...just have to get a couple friends over tomorrow to lift it off.

I assume the dealer will have this crimping type tool so I can replace this small line? Or can I save a few $$ and get it at an auto parts store? If so, what's it called and what's it look like?

Thanks again,

The lines run between the tank and the frame rail..you may end up having to partially drop the tank.
These trucks run fuel pressure of 60-65 psi and if you dead head the pump you can get about 80 or more.
Integrity of the fuel lines is very important! Thats why I only replace the complete assembly.

BOOZER said "If you hack it make sure your insurance is up to date."

Well said!

[Gunn]

Point well taken guys; I want to do this right.

Ok, I think it has finally sunk in! So you guys are saying that I can just remove this flex rubber hose and replace it...I have to remove the part further up and down the line, right!? Sorry about that; I didn't think I was usually that dense

Thanks for helping clear that up. Today I'm going to get the bed off and see how that helps me. Hopefully I can get the line off and to the dealer before they close.

[Gunn]

Just figured I'd update all you guys on what happened.

I did indeed remove the bed of the truck instead. And it was a good thing. Because before I actually started removing things I started up the truck to make sure the fuel leak was coming from that fitting I was talking about. Well, well, it was not. It was actually coming from a pinhole in the steel line coming out of the tank; part of the sending unit. I would have not figured this out otherwise until I replaced the section of line that I thought the leak was in.

So, I had to go to the dealer and purchase a new fuel sending unit...$320.00 bucks! Irritating since the sending unit worked fine. Must have been a poor batch of steel those lines were made out of or something; this truck is driving in S. MD where we get snow (thus salt) only a couple times on average and I pay a great deal of attention to keeping the truck clean.

Anyway, its fixed and on the road again. Thanks for all the help.

PS> Once I got the bed off, I could see exactly what you guys were talking about; that what I thought was a crimped fitting on a rubber line was actually a regular compression fitting attached to the hose...