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Replacing old fuel lines

JPS27

Member III
This is the best picture I have at the moment of this fuel line at bottom of pic. On this fuel line I have a "leak" (moist, like sweating fuel, no drips) at the fitting on the fuel pump on my 1980 Yanmar 2qm15. It's difficult to tell exactly where the leak originates. I've replaced and tightened the washers. I don't think it's leaking at the connection The parts are no longer available. I'd like to replace the similar line at the lift pump because one end of that line looks sketchy as it seems to be deteriorating. Can an auto shop make new ones? What do I need to know/do to get that done correctly. I assume that since the part is not available, then the fittings aren't either. Thanks.
 

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Afrakes

Sustaining Member
Do some online searching. I remember seeing a video of a mechanic replacing the lines utilizing the existing fittings. I believe that the steel tubing can be replaced with copper and the copper brazed to the fittings.
 

JPS27

Member III
Do some online searching. I remember seeing a video of a mechanic replacing the lines utilizing the existing fittings. I believe that the steel tubing can be replaced with copper and the copper brazed to the fittings.
Al, are you referring to the rubber fuel lines? Sorry, working on these is new for me.
 

Loren Beach

O34 - Portland, OR
Senior Moderator
Blogs Author
I replaced all of the fuel lines on my prior '88 Universal diesel, several years ago. Supply and return hoses from tank, and the vent hose. Also all of the short runs around the engine on the filters. I had almost no leaks, but the hose material was looking brittle, and I had already found that an invisible air leak anywhere would air-lock the fuel supply system. I also replaced the deck fill hose.
If your boat still has one of the 80's Racor filter assemblies with the two O rings, replace that with a Racor 500, and considerably reduce the chance of a gasket air leak.

Note that the modern USCG-approved and labeled fuel lines are way better than what was available in the 80's. Look at this sort of project as Preventative Maintenance, and enjoy (if that's the right word) the learning and the labor. It's more labor than parts cost, and you will get much better acquainted with a key system in your boat.
 

Afrakes

Sustaining Member
Al, are you referring to the rubber fuel lines? Sorry, working on these is new for me.
Initially I'm talking about the steel lines. A hydraulic shop might be able replace the rubber fuel lines and salvage the banjo fittings. The copper "crush" washers on those banjo fittings are readily available. Search banjo fittings, there are a number of different options out there.
 
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