Fuel Line/Fuel Rail connector leak

Hello all,

I finally have an issue on the Riv that warrants a new topic. One of the connectors at the fuel rail (can't remember if it's the send or return fuel line) is leaking. It had started leaking a couple months ago when I took apart the top end of the engine to re-gasket, and I thought I had fixed it. To give you an idea, this is what i find every morning.




Dangerous. Anyway, when I had 'fixed' the leak the first time around it almost seemed like that connection wasn't sealing at all when the line was connected back together. I stuck an O-ring in there, of what seemed like proper size, and all was fine for the last 4 or 5 weeks. Now, it's leaking after the pressure from the pump dies down after several hours.

Are there any real fixes for this? Is O-ring material a big factor (it's rubbery - not sure what it's made of) ? Obviously I don't want this problem sitting for too long or it will become pretty 'exciting' at some point, I'm sure.

Thanks for any help, everyone.

-Andrew Z

It shouldn't need an o-ring, and I would suspect the addition of one might not let the fingers clip around the connector flange. When I recently disconnected mine, I noticed there wasn't a solid "click" when reassembling. I pushed it hard, and still didn't feel right. So, I pulled the rail out and used a small screw driver to bend all 4 of the metal fingers so they would click onto the rail connector's flange. Perfect connection after that.

Another solution would be to abandon the OEM lines, and use a SS line with AN-fittings:

https://rivperformance.editboard.com/t3086-write-up-ss-braided-fuel-lines

Thanks Aaron - the clips were a problem at first but then I was able to get all 4 clipped the same day it started leaking and it was fine until now. Nothing's been touched or changed there, and suddenly it's leaking. I didn't think I'd need an O-ring either, as I didn't notice any originally. In an hour or so I'm going to go play with it and see if I see anything obvious.

I like the SS line idea. I suppose some rubber fuel line and some clamps would be last resort, but that's ugly as sin.

That looks like the bigger pressure (3/8) side. You can buy a dorman fuel line repair kit and either cut your line and connect the new one to where you cut. I've done that before on my riv and on a 2001 grand prix with no issues. You also might be able to swap out the guts from the new repair line to your old one. The retainer clip comes out then you can carefully remove the oring section. Either way make sure you use some lubrication on it so it goes on and clicks nice and easy - silglide or petroleum jelly.

I couldn't get a picture of it, but it turns out the connector on the nylon side had a small score where the line would normally seal to the rail. How that happened in the first place, I don't know. Also, it seems the the O-ring I used expanded quite a bit and was basically useless, thus the recent leak after so many weeks.

So, I hopped in another one of our cars and got the last Dorman kit at Advance, got back and installed it in less than 45 minutes. I used a hair drier to heat the connections and it worked wonderfully. No leaks so far, and my fuel pressure is the same at ~42 PSI.

New connector - I like these ones better...they're the same ones I have on my Series I in my T-type from my old Riv.


And here's the line in the engine bay. I don't really like how it's not formed like the old one, but it doesn't look bad, necessarily. I wrapped some electrical tape around the small bit of brass fitting you could see, so it was hidden at least.



Thank you Aaron and Turtle. As much as I would like to have used the original connector, it was damaged but the new repair kit seems to be fine. I'll report back if there are any issues.

Glad to see if was fixed. There's actually like 3 o rings in each line. I have used that same repair kit on my turbo GTP and have yet to have any issues.

That looks like the same connector type used on the fuel filter. Should be easier to remove the line in the future. Looks good, very OEM.

Andrew, how did you make the splice into the original line? Any pictures?

AA wrote:

That looks like the same connector type used on the fuel filter. Should be easier to remove the line in the future. Looks good, very OEM.

Andrew, how did you make the splice into the original line? Any pictures?

The ones that I have looked at include a barb fitting to make the splice.

AA wrote:

That looks like the same connector type used on the fuel filter. Should be easier to remove the line in the future. Looks good, very OEM.

Andrew, how did you make the splice into the original line? Any pictures?

Here's a copy and paste from my build thread on the GP forums:

Fuel has been leaking badly at the top of the fuel rail where the 3/8ths line connects.

Factory line cut:



Replacement line:


Soaking the factory line in boiling water:


Barb fitting in place:


New replacement installed:

I did pretty much the same thing the Jonny did, but I cut the line farther back near the firewall. Sorry, I didnt take any pics because I had to get the thing fixed ASAP, and my camera didn't cross my mind.

To work and back today, everything is good! Certainly an easy repair.