I'm going to put this here before I forget and in hopes that someone who searches this in the future can hit the ground running:
A 95 ZJ (and I suspect most others with the I6) have 2 lines associated with the fuel system: Fuel supply and Vapor return
- The vapor return line is approximately 1/4" and a nylon coupling for fuel lines will work on this line. (see Uniblurb's link above for pic)
- The fuel supply line is 5/16" BUT
at the fuel filter the quick connects are different sizes. Tank side the quick connect is a 3/8" (5/16" line attached). Engine side the quick connect is 5/16" (5/16" line attached).
Most, if not all,part stores don't stock the tank-filter combination
if you are looking to repair your existing line and not drop the tank via chop and replace with a 3/8" quick connect - 3/8" line
. THIS IS BAD NEWS BEARS! You need to use your stock 3/8" quick connect to 5/16" line and heat up some new nylon. You can also get (or order this
or its 90 degree cousin). Be warned, heating the nylon and trying to get it to fit is a royal PITA. (At least my attempts at it this evening failed miserably). The best solution, as many have mentioned is to drop the tank and replace with OEM parts or stainless steel lines or whatever else tickles your fancy.
Nylon Line Heating: So I've done a little research and Nylon's melting point is somewhere in the neighborhood of 500 degrees F. Boiling water is a chilly 212 deg F by comparison. Obviously you don't want to melt the line, but it does need to get warm enough to stretch a little. So some alternative methods for heating would include open flame (this can burn your line), heat gun (or hair dryer?), stove top, or special heat lamps. With these higher temp devices make sure to constantly rotate the tube to ensure even distribution of heat. It also should be noted that heating the fitting would be ideal so as not to create a strong heat-sink and thereby the nylon lose its plasticity/pliability. Results to follow.
Hair Dryer: doesn't get hot enough
Open Flame: must watch very closely or it will overheat and start melting your nylon/fitting
Boiling: I tried placing the end in boiling water on two occasions with no success. The end flared a little but never enough to go over the first barb on the fitting. The pipe was not strong enough to force on the fitting and buckled twice.
Solution: I ended up just going to the junk yard and picking up two of the tank-filter lines off old ZJ's that were still good and splicing one in. Cost me all of $1.75.
If you want to save yourself some trouble and get in a little preventative maintenance, do as Uniblurb said, and go pick up some conduit
as a good first line of defense against pesky rodents nibbling through your fuel line/wires.