Mark VIII V8-4.6L DOHC (1996)
Fuel Return Line: Service and Repair
Repair
Nylon Fuel Lines
Splicing Nylon to Nylon
Splicing Service Combinations
1. Relieve fuel system pressure. If necessary, drain fuel tank.
2. Cut out damaged section of tubing and retain as a guide.
3. Cut a section of service tubing (type 11 or 12 nylon available in 1/4 and 5/16-inch sizes) to the same length as the damaged section of tubing.
NOTE: To make hand-insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one
minute immediately before pushing the barbs into the nylon.
CAUTION: Do not use any heating method except hot water to repair nylon tubing. Temperatures above 100°C (212°F) cause the nylon to soften
and will not seal on the barbed connectors. Replacing nylon line in the engine compartment requires heat protective Hypalon hose.
4. Select the proper (1/4 or 5/16-inch) barbed connectors for completing the splice. Two connectors are required for each splice.
5. Install the barbed connectors into each end of the replacement tubing using boiling water.
6. Install clips onto any tubes which might be difficult to access once the final splices are completed.
