Fuel line crimp leaking after replacing fuel pump

[Tooky]

I'm near the end of the install, finally upgrading my factory 198,625 mile fuel pump which goes lean on the wideband above 14 PSI boost, to the Walbro 255 High pressure unit.  Unfortunately too many Wisconsin salt winters has taken its toll on the undercarriage of my TGP.

When I took the fuel lines apart, they were frozen and I worked them with PB blaster and line wrenches, but nonetheless on two of the factory braided steel "crimp joints", the crimped steel hose started to turn inside the crimp, before the threaded end fitting came unfroze from the flared steel line end.  Now when I finished the project, I reconnected the battery and have fuel leaks at one of the joints. 

Any ideas how I can fix this?  It was a royal pain getting the fuel tank reinstalled; I'm hoping there's another solution besides remove the damn thing again, and attempt to remove & replace the whole 2 foot section over the fuel tank with the damaged end, and hopefully I don't break those fittings when I attempt to remove that joint too!!  I doubt the dealer stocks these lines anymore either.

Here's the photos to illustrate. 

[mfewtrail]

Ouch! I would venture to guess that the line needs to be completely replaced right there in order to fix that.

[GOT2B GM]

Yeah, I dont think there is a way to fix those rotted crimp connections.

[sleeperred90tgp]

Wow, I've never seen anything that rusty. Hope the rest of the car isn't that bad.

Try an industrial tube and hose supply. The braid part isn't a problem thay can make that up in minutes. The top picture go all braid, bottom picture looks like your steel tube is ok.

You can also buy fittings and hose off the net and DIY. I recommend the former.

I have the same problem, can't get more than 50# at any boost. Walbro puts out for awhile and then they crash. I have my 3rd one sitting here to put in as many years. :icon_evil: Just waiting to run out of gas.

Good luck

Jud

[Tooky]

Well I got it fixed, I needed to get the car going since it's my daily driver so I found out the dealer had new lines in stock!!!  Cost me about $60 for the pair.  Here are the part numbers:

10062887 PIPE ASM FUEL RTN
10062888 PIPE ASM FUEL FEED




Here they are installed:




The shitty thing is the new lines are about 1.5" longer than the originals, and the flare that seats the o-ring is a different size (larger than stock by enough to make the stock o-rings slip inside without compressing.  I got a "Dorman products" Fuel Line O-Ring Kit from Advance Auto ($7.44 for 4 o-rings??  :icon_evil:) that had a larger one that fit properly.  Some quality control over there at GM!  The extra length also made the fuel lines interfere pretty badly with the rear brake cable up there, I had to really be careful to jam this all in there when I put the tank back in.  I'm not happy about it but as long as it doesn't rub through and leak I guess it's OK.

[GOT2B GM]

you should paint your tank with POR 15 while its down

[bake82]

that rust is pretty bad.  My original 88 is worse than that, but the rest of my car is basically rust free.  Glad to hear you got it fixed!!