Title: Fuel Line Check Valve Installation
Owner: Don B , added Mar 08 2013 00:17:25
[127]
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3938x1402 229kb(If the image has failed to load, click on it to view large version) Description: The Fuel Check Valve and Fuel Pressure Regulator work together to maintain pressure at the rail for proper engine performance and easier starting. On later XJ40s the valve is built into the in-tank fuel pump housing, so when it fails, it’s easier to simply add a new check valve in the fuel line.
3934x1982 235kb(If the image has failed to load, click on it to view large version) Description: I used a 1/4 in. check valve from McMaster-Carr with a gasoline-safe fluoroelastomer seal. Our ’93 has 8mm I.D. fuel hoses, so I ordered 5/16 in. hose barb fittings, the closest size. The arrow on the check valve body indicates direction of flow. Use Teflon tape on the threads to prevent leaks.
2533x1596 227kb(If the image has failed to load, click on it to view large version) Description: The check valve can be installed at the fuel rail, but this doesn’t allow for the pressurization of much fuel. Long-cranking cold starts will be improved, but not optimally. The best location is as close to the fuel tank as possible to maintain pressure in the entire fuel line from tank to rail.
2530x1750 226kb(If the image has failed to load, click on it to view large version) Description: I followed the line back from the fuel filter and selected a point where the check valve could be supported with minimal modification to the car. I used cable cutters to sever the line at the selected point. No turning back now!
2812x965 230kb(If the image has failed to load, click on it to view large version) Description: It was difficult to insert the hose barbs, so I disconnected the short section of fuel hose from the tank and the longer section from the fuel filter and took them to the bench to install the check valve. Vacuum pump plugs prevented debris from entering the lines while I handled them.
3094x1190 218kb(If the image has failed to load, click on it to view large version) Description: Unlike the fuel hose at the rail, which is reinforced with cloth, the hose under the tank is reinforced with steel braid. It wasn’t easy to insert the hose barbs, so I used a tapered punch and a heat gun to carefully stretch the cut ends of the hose.
3947x898 206kb(If the image has failed to load, click on it to view large version) Description: I padded the check valve with leather and mounted it in the vise, then worked the shorter hose onto one of the hose barbs. Even after stretching the hose it wasn’t easy to get it on the barb.
1650x2762 224kb(If the image has failed to load, click on it to view large version) Description: Then I mounted the short hose and check valve in the vise as shown and pushed and twisted the longer hose onto the other barb.
2400x1367 216kb(If the image has failed to load, click on it to view large version) Description: On our ’93, the hose is routed through openings in the frame as it passes from the tank to the fuel filter. The hose clamps kept catching on things as I tried to fish the hose through the frame, so I temporarily removed them and reinstalled them after the hose was in place.
1400x1199 226kb(If the image has failed to load, click on it to view large version) Description: I felt the check valve should be immobilized to reduce vibration that might cause leaks by weakening the hose-barb junctions. I drilled four holes in the heat shield and threaded wire ties through them to secure the valve. The heat shield will pull downward for access.
2000x1001 239kb(If the image has failed to load, click on it to view large version) Description: The check valve installed and secured with wire ties. I installed the valve while the IRS was removed for overhaul, so I had free access to the fuel line beneath the tank. I took advantage of this access to also replace the O-rings on both fuel line fittings (two O-rings per fitting).
1900x1543 215kb(If the image has failed to load, click on it to view large version) Description: It won’t be as easy to install a valve with the IRS in place, but if you remove the fuel line to insert the valve, the only challenge is how to immobilize the valve to protect against leaks caused by vibration. Alternately, it might be possible to install the valve on the outer side of the frame.
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