Okay, before I get too far into this installation, Team VETTE has officially nixed the moniker "The Phoenix" in favor of "The Zombie." That's right, we've renamed my C4 in favor of something that seems more fitting. For those of you unfamiliar with the history of The Zombie, the '87 is a wreck-bought-cheap from a friend. With backend damage that was easily repairable, it seemed like a good entry-level Corvette that would be an inexpensive fix. While I still stand behind that idea, the accident shook loose the car gremlins, and they've been making life hell for us since. Case in point...
Recently, while doing a brake and rotor story, a jack that was being used to hold up the car broke. That sent the wheels it rode on in opposite directions and caused the Vette to shift its weight, which in turn caused a misplaced jack stand to push right up into the fuel line-crimping the line and crippling the car. This is a fancy way of saying, "I dun' screwed up and jacked a fuel line."
Since we're working from the...
Since we're working from the damage forward, we cut the fuel lines, provided by J&D Corvette of Bellflower, CA, roughly in half (arrow).
While most might consider this a matter of pride and keep it under wraps, I say nay and fully launched myself into discovering the best way to repair the damaged lines. After all, if I'm going to screw it up, I'm going to learn a few things about the repair process. A quick call was put into J&D Corvette of Bellflower, California, and they pulled the fuel lines I needed for my year Corvette. Speaking of years, it'll take anybody about that long to do a full removal, so we opted to repair everything from the damage forward instead of taking the entire rear of the Vette apart. Anyone who's worked on the rear understands our reasoning since the Corvette seems built around the lines itself and would involve removal of the entire suspension system to get at them.
Did it work? We'd like to say yes, but the fact of the matter is The Zombie's "car voodoo" has kept us from testing the new lines as an unrelated problem with the gas tank meter and sending unit has given rise to a tech story next issue. Stay tuned; we'll resurrect this wreck yet!
Since this was just a pre-fit...
Since this was just a pre-fit cut, we figured out roughly what we needed, taped it off, and got started with a saw.
The lines under the passenger's...
The lines under the passenger's side of the newly renamed "Zombie" received the same treatment with a small pipe cutter. Pressure relief or not, these lines will still have fuel in them, so be ready for a decent amount to spill out.
With the lines cut and unattached...
With the lines cut and unattached from the '87, Jason Scudellari, our Tech Center installer for this round of repairs, removed them from the Vette itself.
The horizonal lines.
While we were at it, we replaced...
While we were at it, we replaced the fuel filter. This standard-issue part can be found at just about any automotive parts store.
Next, Jason fit one of the...
Next, Jason fit one of the lines roughly into place.
Then, we made some measurements...
Then, we made some measurements for fitting.
After carefully cleaning up...
After carefully cleaning up the cut with a file, the pressure fitting was installed on one side of the hose and torqued down followed by the same treatment on the other side.
With the line pulled back...
With the line pulled back out of the car, a pipe cutter was used to remove the excess tubing.
Here's what it'll look like...
Here's what it'll look like when you're finished.
Nothing different with installation...
Nothing different with installation on the other line except tube size. Here, Jason pre-fits everything after cutting the fuel line.
Jason next installed the second...
Jason next installed the second line in the same manner.
Pressure is important. Too...
Pressure is important. Too much and you'll leak. Not enough and the same thing will happen.
With the old one out, and...
With the old one out, and the new one in, we wrapped up the install and carefully reattached the lines to the frame the same way they came off. Did our operation work? I wish I knew, the gas tank meter and sending unit decided to take a permanent vacation. Join us next month as we finish up.
Once again, torque it down,...
Once again, torque it down, do the other side, and you're all set. Don't forget to check for leaks.