Changed fuel filter and now it's leaking like crazy

[MCgrease08]

Reviving an old thread so I can post about my stupidity when trying to do this job so others may learn from my mistakes.

I thought I was doing everything right. I ordered an OEM fuel filter, as well as line wrenches. I also sprayed fittings on both sides of the old filter with PB Blaster multiple times over several days before starting the job. I watched Timmy's video several times (posted uptread) before starting.

The line from the tank to the filter came off with no issue. Like many others, it was the line from the filter to the engine that was seized. I took it easy at first, spraying more PB Blaster and waiting. Spraying more PB Blaster and waiting. The angle of the wrenches with the cross member in the way sucks, so even with two line wrenches, the leverage was pretty weak because the head of the 14mm was flexed.

Eventually with brute force I managed to get the outlet side fitting out. And I had only knocked the catch pan with fuel onto myself once during the process.

"The hard part is over," I thought. Wrong. Reassembly turned out to be my downfall. Apparently my monster strength in getting the fitting out slightly bent the fuel line. It changed the geometry just enough that I didn't realize it. When I went to thread the outlet side side back in to the new filter, it must have been off center by a hair, because it was tight going in for the first couple of threads when hand tightening. (You can guess where this is going.)

I ended up cranking down on the fitting pretty good with the wrench but it never felt like it got stopped or bound up. Anyway. It all went back together and nothing leaked when I reconnected the power to the fuel pump and repressurized the lines. I took the truck for a trip around the neighborhood for a shakedown and was only after I got back that I noticed a pretty major gas leak.

Took everything back apart and drained the fuel lines again. Figured I just needed to try again and reseat the fitting. No luck. I guess I cross threaded the first two or three threads inside the filter. Now it won't go back together at all.

There isn't a fast way to tap the threads either because m14 x 1.5 isn't a common tap size that hardware stores or auto parts stores carry, plus most taps are tapered, and the depth of the filter opening is too shallow to be able to get the tap in deep enough to clean up the first 2-3 threads. Probably could find a special order tap if I felt like waiting around, which I don't.

I don't think I stripped the threads on the fuel line fitting, but ordered a new OEM top line just to be safe. My truck is a total rust bucket so it's not gonna hurt to have a new line. Also bought another fuel filter.

Oh, did I mention this is my only vehicle now since my DD got totalled out after getting t-boned last month?

That means in addition to having to buy a second fuel filter and new line, I also had to rent a car for a few days until the parts come in. So this $50 job is going to cost me at least $400 after I get done paying all of the stupid tax. Good greif, I just want one project on this rig to go smoothly. Everything except fluid changes has been three times as hard as I antipicated.

Learn from my screw up. Go slow with the fittings. If in doubt, back it out and start again.

 

[brillo_76]

Reviving an old thread so I can post about my stupidity when trying to do this job so others may learn from my mistakes.

I thought I was doing everything right. I ordered an OEM fuel filter, as well as line wrenches. I also sprayed fittings on both sides of the old filter with PB Blaster multiple times over several days before starting the job. I watched Timmy's video several times (posted uptread) before starting.

The line from the tank to the filter came off with no issue. Like many others, it was the line from the filter to the engine that was seized. I took it easy at first, spraying more PB Blaster and waiting. Spraying more PB Blaster and waiting. The angle of the wrenches with the cross member in the way sucks, so even with two line wrenches, the leverage was pretty weak because the head of the 14mm was flexed.

Eventually with brute force I managed to get the outlet side fitting out. And I had only knocked the catch pan with fuel onto myself once during the process.

"The hard part is over," I thought. Wrong. Reassembly turned out to be my downfall. Apparently my monster strength in getting the fitting out slightly bent the fuel line. It changed the geometry just enough that I didn't realize it. When I went to thread the outlet side side back in to the new filter, it must have been off center by a hair, because it was tight going in for the first couple of threads when hand tightening. (You can guess where this is going.)

I ended up cranking down on the fitting pretty good with the wrench but it never felt like it got stopped or bound up. Anyway. It all went back together and nothing leaked when I reconnected the power to the fuel pump and repressurized the lines. I took the truck for a trip around the neighborhood for a shakedown and was only after I got back that I noticed a pretty major gas leak.

Took everything back apart and drained the fuel lines again. Figured I just needed to try again and reseat the fitting. No luck. I guess I cross threaded the first two or three threads inside the filter. Now it won't go back together at all.

There isn't a fast way to tap the threads either because m14 x 1.5 isn't a common tap size that hardware stores or auto parts stores carry, plus most taps are tapered, and the depth of the filter opening is too shallow to be able to get the tap in deep enough to clean up the first 2-3 threads. Probably could find a special order tap if I felt like waiting around, which I don't.

I don't think I stripped the threads on the fuel line fitting, but ordered a new OEM top line just to be safe. My truck is a total rust bucket so it's not gonna hurt to have a new line. Also bought another fuel filter.

Oh, did I mention this is my only vehicle now since my DD got totalled out after getting t-boned last month?

That means in addition to having to buy a second fuel filter and new line, I also had to rent a car for a few days until the parts come in. So this $50 job is going to cost me at least $400 after I get done paying all of the stupid tax. Good greif, I just want one project on this rig to go smoothly. Everything except fluid changes has been three times as hard as I antipicated.

Learn from my screw up. Go slow with the fittings. If in doubt, back it out and start again.

Oh I actually twisted those front lines off trying to get them loose. I actually antiseize those threads on filter, and I am wondering if I should not coat them in mp grease.

I'm sorry to hear that. For whatever reason, that front line in the filter is the worst. Granted, none of mine have the fuel filter cover left, plus I am sure the rust belt makes mine worse.

What's really bad is when you out of backup rides. Man I been there too many times. That I actually try to keep 2 spares on standby. So I am never without wheels. The last few years make it harder to keep a spare or 2 around.

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[JoeT4R]

Reviving an old thread so I can post about my stupidity when trying to do this job so others may learn from my mistakes.

I thought I was doing everything right. I ordered an OEM fuel filter, as well as line wrenches. I also sprayed fittings on both sides of the old filter with PB Blaster multiple times over several days before starting the job. I watched Timmy's video several times (posted uptread) before starting.

The line from the tank to the filter came off with no issue. Like many others, it was the line from the filter to the engine that was seized. I took it easy at first, spraying more PB Blaster and waiting. Spraying more PB Blaster and waiting. The angle of the wrenches with the cross member in the way sucks, so even with two line wrenches, the leverage was pretty weak because the head of the 14mm was flexed.

Eventually with brute force I managed to get the outlet side fitting out. And I had only knocked the catch pan with fuel onto myself once during the process.

"The hard part is over," I thought. Wrong. Reassembly turned out to be my downfall. Apparently my monster strength in getting the fitting out slightly bent the fuel line. It changed the geometry just enough that I didn't realize it. When I went to thread the outlet side side back in to the new filter, it must have been off center by a hair, because it was tight going in for the first couple of threads when hand tightening. (You can guess where this is going.)

I ended up cranking down on the fitting pretty good with the wrench but it never felt like it got stopped or bound up. Anyway. It all went back together and nothing leaked when I reconnected the power to the fuel pump and repressurized the lines. I took the truck for a trip around the neighborhood for a shakedown and was only after I got back that I noticed a pretty major gas leak.

Took everything back apart and drained the fuel lines again. Figured I just needed to try again and reseat the fitting. No luck. I guess I cross threaded the first two or three threads inside the filter. Now it won't go back together at all.

There isn't a fast way to tap the threads either because m14 x 1.5 isn't a common tap size that hardware stores or auto parts stores carry, plus most taps are tapered, and the depth of the filter opening is too shallow to be able to get the tap in deep enough to clean up the first 2-3 threads. Probably could find a special order tap if I felt like waiting around, which I don't.

I don't think I stripped the threads on the fuel line fitting, but ordered a new OEM top line just to be safe. My truck is a total rust bucket so it's not gonna hurt to have a new line. Also bought another fuel filter.

Oh, did I mention this is my only vehicle now since my DD got totalled out after getting t-boned last month?

That means in addition to having to buy a second fuel filter and new line, I also had to rent a car for a few days until the parts come in. So this $50 job is going to cost me at least $400 after I get done paying all of the stupid tax. Good greif, I just want one project on this rig to go smoothly. Everything except fluid changes has been three times as hard as I antipicated.

Learn from my screw up. Go slow with the fittings. If in doubt, back it out and start again.

It happens brother. I've done the fuel filter job three times on my truck, but the last time I did it I ran into the same problem that you did. Ended up having to get my truck towed in and everything. New fuel lines and a new filter ended up going in. That's probably the last time that I'll touch my fuel filter. I've got 332K miles on my truck so I must be doing something right. Here's a link to the post about it in my build thread.

https://www.toyota-4runner.org/3761188-post121.html

 

[octanejunkie]

Reviving an old thread so I can post about my stupidity when trying to do this job so others may learn from my mistakes.

I thought I was doing everything right. I ordered an OEM fuel filter, as well as line wrenches. I also sprayed fittings on both sides of the old filter with PB Blaster multiple times over several days before starting the job. I watched Timmy's video several times (posted uptread) before starting.

The line from the tank to the filter came off with no issue. Like many others, it was the line from the filter to the engine that was seized. I took it easy at first, spraying more PB Blaster and waiting. Spraying more PB Blaster and waiting. The angle of the wrenches with the cross member in the way sucks, so even with two line wrenches, the leverage was pretty weak because the head of the 14mm was flexed.

Eventually with brute force I managed to get the outlet side fitting out. And I had only knocked the catch pan with fuel onto myself once during the process.

"The hard part is over," I thought. Wrong. Reassembly turned out to be my downfall. Apparently my monster strength in getting the fitting out slightly bent the fuel line. It changed the geometry just enough that I didn't realize it. When I went to thread the outlet side side back in to the new filter, it must have been off center by a hair, because it was tight going in for the first couple of threads when hand tightening. (You can guess where this is going.)

I ended up cranking down on the fitting pretty good with the wrench but it never felt like it got stopped or bound up. Anyway. It all went back together and nothing leaked when I reconnected the power to the fuel pump and repressurized the lines. I took the truck for a trip around the neighborhood for a shakedown and was only after I got back that I noticed a pretty major gas leak.

Took everything back apart and drained the fuel lines again. Figured I just needed to try again and reseat the fitting. No luck. I guess I cross threaded the first two or three threads inside the filter. Now it won't go back together at all.

There isn't a fast way to tap the threads either because m14 x 1.5 isn't a common tap size that hardware stores or auto parts stores carry, plus most taps are tapered, and the depth of the filter opening is too shallow to be able to get the tap in deep enough to clean up the first 2-3 threads. Probably could find a special order tap if I felt like waiting around, which I don't.

I don't think I stripped the threads on the fuel line fitting, but ordered a new OEM top line just to be safe. My truck is a total rust bucket so it's not gonna hurt to have a new line. Also bought another fuel filter.

Oh, did I mention this is my only vehicle now since my DD got totalled out after getting t-boned last month?

That means in addition to having to buy a second fuel filter and new line, I also had to rent a car for a few days until the parts come in. So this $50 job is going to cost me at least $400 after I get done paying all of the stupid tax. Good greif, I just want one project on this rig to go smoothly. Everything except fluid changes has been three times as hard as I antipicated.

Learn from my screw up. Go slow with the fittings. If in doubt, back it out and start again.

Way too much to read... you good now?

 

[MCgrease08]

It happens brother. I've done the fuel filter job three times on my truck, but the last time I did it I ran into the same problem that you did. Ended up having to get my truck towed in and everything. New fuel lines and a new filter ended up going in. That's probably the last time that I'll touch my fuel filter. I've got 332K miles on my truck so I must be doing something right. Here's a link to the post about it in my build thread.

https://www.toyota-4runner.org/3761188-post121.html

Brutal. The tow and professional fix is what I'm trying to avoid.

I'm getting married in less than two weeks and I'll be moving about an hour away to where my finace lives, so there is a lot going on with wedding planning and moving prep. My lady was less than happy when I told her I wouldn't be able to come up to see her on Sunday. Her comment was something to the effect of, "at what point will you let someone that knows what they're doing fix it?" out:

I was like, "I have a plan and new parts on order."

Pretty sure I could hear her eyes rolling over the phone.

 

[octanejunkie]

At 70 PSI there's no avoiding a leak if the compression fittings don't hook up 100%.

As much as all of that sucks, if you think you just bundled up a filter and the fitting is okay, how about just a new filter, a thread chaser to clean up the male compression fitting and some thread sealant?

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[JoeT4R]

Brutal. The tow and professional fix is what I'm trying to avoid.

I'm getting married in less than two weeks and I'll be moving about an hour away to where my finace lives, so there is a lot going on with wedding planning and moving prep. My lady was less than happy when I told her I wouldn't be able to come up to see her on Sunday. Her comment was something to the effect of, "at what point will you let someone that knows what they're doing fix it?" out:

I was like, "I have a plan and new parts on order."

Pretty sure I could hear her eyes rolling over the phone.

Understandable. Do you have AAA? That's what I used. The professional fix was costly but fast and done the right way. At that time in my life I didn't have the time and ability to do it myself unfortunately. Sounds like you're in a similar pinch. But, if you've got a plan and parts on order then at least you're on the right track to making it happen. Luck and best wishes brother. Keep us updated.

 

[MCgrease08]

At 70 PSI there's no avoiding a leak if the compression fittings don't hook up 100%.

As much as all of that sucks, if you think you just bundled up a filter and the fitting is okay, how about just a new filter, a thread chaser to clean up the male compression fitting and some thread sealant?

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That's the plan as far as things to try first. I don't want to install new fuel line if I can avoid it, and the male fitting looks to be OK. It certainly doesn't hurt to have the new line in inventory for down the road, or if that doesn't work out.

 

[brillo_76]

That's the plan as far as things to try first. I don't want to install new fuel line if I can avoid it, and the male fitting looks to be OK. It certainly doesn't hurt to have the new line in inventory for down the road, or if that doesn't work out.

I actually made a new line out of nickle copper out of the sending unit as the nipple got jacked up on my 1997 5 speed. As you can make your own front line fuel line. I would want a stainless steel nipples though.

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[gamefreakgc]

Hey at least you didn't strip the compression nut like I did. Had to tighten it back down with vicegrips and now you can't even call it a nut anymore. More like a piece of mangled steel.

Same happened to my fuel line going into the engine bay that comes up on the driver's side when I swapped engines. Brake line wrench bent and bit into the metal when it tightened it back up. The wrench was stuck on the fuel line for about a year after I was done! Eventually the heat cycles and vibrations loosened it so I could remove it and not look ghetto. Those fuel lines are a real fight after 25 years.

 

[MCgrease08]

That's the plan as far as things to try first. I don't want to install new fuel line if I can avoid it, and the male fitting looks to be OK. It certainly doesn't hurt to have the new line in inventory for down the road, or if that doesn't work out.

I tried a thread file on the old fitting but it was still giving me too much resistance when trying to thread it into the new fuel filter so I stopped for fear of cross threading it again. Just gonna wait unit new OEM hard line gets here which hopefully will be today.

I plan on cutting the old line out in sections to make it easier to get it out. The brackets holding it in place are likely super brittle. I figure if I cut the line into sections I can probably just slide each section out of the brackets. But I'm not super confident about how to install the new fuel line. Any tips from anybody that's replace the fuel line from the filter up to the engine?

 

[brillo_76]

I tried a thread file on the old fitting but it was still giving me too much resistance when trying to thread it into the new fuel filter so I stopped for fear of cross threading it again. Just gonna wait unit new OEM hard line gets here which hopefully will be today.



I plan on cutting the old line out in sections to make it easier to get it out. The brackets holding it in place are likely super brittle. I figure if I cut the line into sections I can probably just slide each section out of the brackets. But I'm not super confident about how to install the new fuel line. Any tips from anybody that's replace the fuel line from the filter up to the engine?

I have changed 2 front lines. Believe it or not, you wiggle and jiggle the line in from the engine compartment it will go in.


Will be easier if you have it on jack stands off the ground to work it both ways but you can do it sitting on the ground.

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[MCgrease08]

She's all back together and leak free.

I cut the ends to release the old fittings and pulled the old fuel line over my lunch break. Simple enough and I only snapped two of the plastic brackets I think.

New fuel line was delivered around 2:30 p.m. and I think I had it installed and new new filter on by 3:00. It all went much more smoothly than I expected considering all of the other hassle involved up unitl now.

I did a shakedown around the neighborhood. All the gas is still inside where it's supposed to be. I'm happy.

 

[brillo_76]

She's all back together and leak free.



I cut the ends to release the old fittings and pulled the old fuel line over my lunch break. Simple enough and I only snapped two of the plastic brackets I think.



New fuel line was delivered around 2:30 p.m. and I think I had it installed and new new filter on by 3:00. It all went much more smoothly than I expected considering all of the other hassle involved up unitl now.



I did a shakedown around the neighborhood. All the gas is still inside where it's supposed to be. I'm happy.

Good job...

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