XK8 / XKR ( X100 ) 1996 - 2006

Replacement plastic fuel filter/line connector - RESOLVED

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Old Aug 24, 2020 | 11:36 AM
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Default Replacement plastic fuel filter/line connector - RESOLVED

Sorry if this has been asked before but didn't see it in a search. One of the plastic clips on the fuel line that connect to the filter broke on my 2006 XK8 and I'm wondering if there is a good source besides the dealer. Luckily it's the bottom one so easy to get to.

You can see in the pictures it cracked at the top and the little plastic retaining clip inside is gone now. That plastic line it is attached to is a short 10-12” length that then attaches to the main fuel line clipped to the frame and running to the engine. These filters are a standard barb type so would imagine any that fit would work, but would be nice to have the correct one so they match, use the same release, tool, etc.To that point, these in the link below from O’Reilly’s look different but might work, too:

https://www.oreillyauto.com/detail/b...onnector&pos=6



 

Last edited by GGG; Oct 7, 2020 at 05:25 AM. Reason: Add "RESOLVED" to thread title
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Old Aug 25, 2020 | 10:27 AM
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I decided the best replacement is the Dorman 800-081, in part because the insert that comes with the Wix fuel filter is for this style connector. $7 beats the ******* trying to sell me an entire new fuel line to the front of the car for $110.
https://www.oreillyauto.com/detail/b...0+degree&pos=0
 

Last edited by DougBoost; Aug 26, 2020 at 08:05 AM.
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Old Aug 25, 2020 | 10:52 AM
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Hope it works for you. Keep us posted....
 
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Old Oct 6, 2020 | 05:24 PM
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It wasn't easy but finally got it. I can see why Jaguar only sells the complete line, though that is not easy, either. This vinyl tubing needs to be heated with a heat gun (forget the boiling water some internet people suggest) but it will also suddenly collapse/crimp on you. Avoid pliers at all costs and get extra line to practice with since you will need it.

I tried creating my own holding block per some things I read on the Porsche and LS forums but the tubing still slipped once you really got to pushing it fully on -- worked ok initially but to get over all 3 barbs it wasn't happening. And it REALLY failed when I went to push the other end on to the metal fuel line running forward to the engine.

I found I had to use the Dorman install kit. It's not the best but it's better than anything you will cobble together and it will work. It wasn't worth $90 for one fittings, so I racked my brain and remembered I had a friend who has a shop. He he had the kit and let me come in and use it, so I put the 90 degree fitting on pretty easily with it. Before installing this on the car I did a test fit of tubing metal fuel line running forward to the engine.

First thing was to clamp it in my split wooden block holder I custom made per the forums. I then put this in a vice and heated with low setting on my heat gun. I then inserted a medium phillips screwdriver to open the end up a bit, followed by a large one, so it could now get started on the metal line. I then lubed it with some vaseline and heated with a heat gun, and slow and steady was able to push it on.I was successful so cut that off, then cut the line with the fitting to length and proceeded to install the real thing. I couldn't even get it half on the metal line before it slipped in the wooden block. Then the tubing collapsed and crimped flat...ARGHH!. Which also meant the fitting had to be removed and installed on a new line.

So back to his shop to beg me to let me take the tool home. He is not in the tool rental business but understood the limited value of me buying the kit (he's only ever used it once!) so let me borrow it. I knew I had to start with the fuel line end since the tool is pretty good at putting the plastic fitting on. There was no way to use the tool's clamp for the metal fuel line, due to the way the metal line goes from small to medium to large. No matter which combo of holes I tried it slipped. But the clamp/holding tool was good enough that I could hold it in my hand, and by going slow and in small increments I finally got it pushed on. Then was a simple matter to cut line to length and use the tool to press the 90 degree fitting on (it really is as easy as the online video shows, once you get the tool set up and fitting aligned PERFECTLY). The Dorman tool also comes with some nice fuel injection clamps you crimp on for added security.

The end result if professional and you'd never know. I upgraded to the GM style fitting for it so it never happens again (and since the clips for that style fitting come in every replacement fuel filter I've bought)..



 
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