How much fuel pressure does the return line have on a 96 cavalier?

[Talon69]

How much pressure does the return line have on a 2.2 96 cavalier?

Why i ask is because i just put a new tank in my car but now have another problem. I tried to take the quick coupling apart on the return by the tank but to rusted to get out. So i dropped the tank be careful not to pull to much on the line. Got the new tank up started it up and now the RETURN LINE leaks out of that quick coipling. So i played around with it and twisted it off!!

I cannot get it out, tried for roughly 2 hours. Now since you cannout by that plastic line seperate, i have 2 choices, 1 by a hole complete sending unit( not gonna happen) or 2 cut that bad fitting off and cram a fitting that has ribs on it inside the plastic hose and clamped it. Heat the plastic hose up with very hot water to make it where it will stretch a bit.

Thanx

Eric

[rhandwor]

I think what you are talking about will work. Another option is go to a scrap yard and get a section of hose. Cut the tubing about two inches from the end of the hose. Get two copper connectors with crimp fittings on each end I think 5/16 inch this will attach the hose. I've seen people buy a copper crimp elbow and use it when cutting a hole in the bed of a pickup they cut the line. You can also buy goodyear hose rated for a 100psi for fuel line. It also has a plastic insert.
Did you break the line or is the connector itself leaking. The copper fittings you can get at the hardware.

[Talon69]

the line started leaking right at the connector after to much stress i guess. So i tried to get the pipe loose in the connector on the plastic hose but the pipe twisted off.

So cutting the connector off on the plastic tube and putting a fitting in there with high pressure hose will work? and clamped onto the pipe?

[rhandwor]

Air conditioning hose will hold with hose clamps which is higher pressure. The return line is open to the tank after the pressure regulator. The manufacturer uses a good quality crimp fitting. But a good quality high pressure hose and hose clamp should hold. You can buy high pressure hose from ebay suppliers.
I would go to U-pull it and find a chev. malibu and snip a piece of hose at the metal lines and go to Home Depot or Lowes and buy two copper crimp splicers.
Sometimes a scrap yard is a good source for parts that fit. I have used hose clamps on air hose carrying over 100psi and they held. These fittings might work.

[Talon69]

Ok i am going to the parts store this morning to get piece of high pressure hose. I called Autozone and that shit is $7 a foot and i only need like 5 inches lol. Then i will go over to lowes and get some fittings if autozone does not have anything for me in that department.

Thank you for the good info

I will let you know how it turns out, the only problem i see is getting a fitting inside that plastic, but the boiling hot water should do the trick to make it more flexible.

Eric

[Blue Bowtie]

Aside from frictional losses in the line and fittings, there is no pressure in the fuel return line. The line would be subject to tank pressure only,and that is limited to under 2 PSIG by the tank pressure control valve in the EVAP system. That said, there is potentially significant FLOW in the return line, but not pressure. Choose your connections and hoses accordingly.

[Talon69]

all fixed!! works perfect, i got all the fittings,clamps and 250psi fuel line all at Lowes for under $5

Thanx for the help guys

[rhandwor]

It supprised me Auto Zone was so much higher than Lowes. I'm glad it is fixed.

[Talon69]

Originally Posted by rhandwor

It supprised me Auto Zone was so much higher than Lowes. I'm glad it is fixed.

Yeah fuel injection hose at lowes is only 84 cents a foot