Stripped flare fittings while installing Wally 255?

[alice]

I searched and found a couple ideas and solutions to my problem but I need a little more input.

Last night, I was shooting to get the Walbro 255 installed on my 2g AWD. I went to undo the flare fitted hard line from the rubber line under the car and of course, the flare fitting stripped out. Mad Then I tried vice grips to no avail so I have concluded that I'm beat.

I plan on just cutting the hard line under the car and on the sending unit and replacing the stock rubber line with new high pressure fuel hose and clamps. Any suggestions to this process? Clamping, should I use two clamps on each end? Any input is greatly appreciated. Thank You -Jeremy

 

[KYNgsx]

I had the same problem with my stock line. Here's a good guide on how to upgrade to -6AN lines:

http://www.dsmtuners.com/forums/articles-engine-fuel/254501-high-flow-fuel-set-up.html

The only clamps used are on the short line in the tank that goes directly to the fuel pump.

 

[alice]

Has anyone else had to do this to their 2g? I am not sure how different the 1g and 2g sending units are so I cant tell if it's possible with the 2g.

 

[housegsx]

Use a pipe wrench. It should grab.

 

[alice]

I am going to try a few other things before I start chopping. I am soaking the fitting in PB Blaster for a few days then I will go for the vice grips or pipe wrench. Hopefully, I don't break the hard line.

 

[deflator]

I trashed my lines trying to get them off too. They were so frozen even with 2 weeks of PB application and 2 people pulling pipe wrenches opposite directions it didn't budge, all it did was warp the line.

I cut the line at the lower fitting and at the fuel filter, removed the filter, and did this...

http://www.dsmtuners.com/forums/bolt-tech/276110-custom-fuel-system.html

I made some mistakes on that setup however. You need a 10 micron filter, and for a 2g its better to weld a bung on the top of the pump assembly rather than cutting all the way through it and rewelding. The other posts on that thread show a better solution for the fitting on the assembly.

 

[DSM Jeff]

I'm running all new -6 line on my 1g for the same reason. In talking to a kid on a local CT forum he ran new -6 line on his 2g. He used a -8 bulk head into the sending unit. Drilled the end that sits in the tank to accept the o-ring for the fuel pump. Then he used a -8 to -6 reducer, and ran -6 line up to a highflow filter and then the rail.

 

[gsxtasy]

Have you tried a flare wrench, which happens to be made for....flare fittings.

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[KYNgsx]

Tried that, didn't work.

 

[gsxtasy]

Ah shoot, those fuel fittings can be stubborn bitches. Hope you get it figured out, if not, new fuel lines! Good luck.

 

[deflator]

Have you tried a flare wrench, which happens to be made for....flare fittings.

Those worked worse for me than pipe wrenches. I actually rounded the lower fitting with a flare wrench somehow

 

[gsxtasy]

Those worked worse for me than pipe wrenches. I actually rounded the lower fitting with a flare wrench somehow

WTF were you doing? Haha, well they worked for me. Hah!

 

[deflator]

After 2 weeks of not budging it, I was going all out no mercy on the fitting. I then got my buddy to pull a pipe wrench one direction, while I pulled another the other we actually cracked the hardline in a couple places and the fitting is still there to this day

 

[alice]

Have you tried a flare wrench, which happens to be made for....flare fittings.

I tried that. I had to buy them new. Craftsman 19mm and 14mm and I stripped the 14mm flare fitting on the hard line under the car.

So pretty much just patching it with rubber line is a no go. I gotta get the new fuel line and filter set-up because it seems as if I am out of luck. Before I drop the money for fittings, lines, and filter, has anyone used new hard lines with compression fittings to fix it?

I was just reading another post about my issue and came to realize that I may have been rotating the wrong flared end. So, on the sending unit side do you turn the 19mm wrench and hold the 14mm or vice-versa. It looks like the fitting is brazed to the metal line from the sending unit anyway so the only choice would be to rotate the 19 and hold the 14. Thanks for all the great replies so far!!

 

[deflator]

I tried that. I had to buy them new. Craftsman 19mm and 14mm and I stripped the 14mm flare fitting on the hard line under the car.

So pretty much just patching it with rubber line is a no go. I gotta get the new fuel line and filter set-up because it seems as if I am out of luck. Before I drop the money for fittings, lines, and filter, has anyone used new hard lines with compression fittings to fix it?

Exactly what happened to me. I had to apply so much force I stripped the lower fitting. Go -6 AN Lines or -8 AN lines get some big injectors and run E85

 

[alice]

I just got a set of PTE 880s which I don't think would be big enough to run e85. And, there isn't much e85 around my area. I plan on giving it another shot when I get home in a day. If not, I will just run -6an to the rail with the necessary components ie: filter, fittings, etc. I assume -4an would be too small?

 

[gsxtasy]

I just got a set of PTE 880s which I don't think would be big enough to run e85. And, there isn't much e85 around my area. I plan on giving it another shot when I get home in a day. If not, I will just run -6an to the rail with the necessary components ie: filter, fittings, etc. I assume -4an would be too small?

880's are good to about 39 lb/min at 80% IDC and 49 lb/min at 100% IDC. So depending on what turbo you have will decide how far you can push them. And yes -4 AN is too small.

 

[alice]

E316g so I don't think I will ever run the 880s @100% IDC. I am shooting for around 85% IDC max or less and if my fuel calculations are correct, they won't be pushed much past 80% IDC @ 18psi. Either way, I will be going the -6an route from sending unit to rail if I can't get the fittings apart. I see most people here run either -6an or -8an fuel lines but most are trying to run double pumps, ethanol, or just a ton of fuel. -6an should be plenty for basically replacing the stock fuel supply line correct? Thanks for the help!!

 

[deflator]

Yeah -6AN isn't much of an upgrade over the stock lines. I think its like a few cm extra inner diameter.

 

[gsxtasy]

Yeah -6AN isn't much of an upgrade over the stock lines. I think its like a few cm extra inner diameter.

A few cm extraWTF. It's maybe a few mm extra, on a 2g that is, 1g's have bigger lines from the factory, and it's not that big of an upgrade. The fuel lines aren't the restrictive part in the first place, the fuel filter is, however if you need new fuel lines anyway, the -6 will work fine.

Oh and by the way, my post about the injector duty is running e85, that is not the duty cycles you'll see with gas.