Subaru Forester fuel leak. My solution: Comments or Ideas?

[Hydrocket]

My Subaru Forester winter "beater" is leaking fuel. It's the return line. As luck would have it, the leak is in a place that is inaccessible....you have to drop the tank to get to it. I don't want to drop the tank. So I was thinking of the following solution:

There is room to add in a new fuel line (125 psi injector line) directly from the pump and snake it though and attach it to the accessible area of the hard lines. I don't see any issues, though maybe in my annoyed state I'm not thinking this all the way though.

I've included pictures of the areas in question.

Is this is viable solution?

[sc_rufctr]

What I would do is drop the tank and replace the line. Painful but worth it IMO.

Your solution may work fine but I really don't think it's a good idea to modify the fuel system in any car.

[Hydrocket]

Originally Posted by sc_rufctr

What I would do is drop the tank and replace the line. Painful but worth it IMO.

Your solution may work fine but I really don't think it's a good idea to modify the fuel system in any car.

I'm not modifying it per se. The original line runs from fuel tank to fitting anyways.

The car is a winter beater and has seen salted roads since 1998. I'm not sure if any of the bolts would even come off (or might break off) in trying to remove the fuel tank. Lots of effort and potential problems for a mere fuel return line on a beater.

To me, it came down to "risk vs reward".

But thank you very much for your reply.

[Nostril Cheese]

If its just the return line, I dont see any problem. If you end up cutting the hard line, make sure you double hose clamp it. Or if there's room, flare the end of the line.

[Hydrocket]

Originally Posted by Nostril Cheese

If its just the return line, I dont see any problem. If you end up cutting the hard line, make sure you double hose clamp it. Or if there's room, flare the end of the line.

Excellent advice.

Thanks!

[sc_rufctr]

You're welcome but how do you know the return line is the only line with any issues?

I don't mean to be pedantic but it is fuel after all.

[Hydrocket]

Originally Posted by sc_rufctr

You're welcome but how do you know the return line is the only line with any issues?

I don't mean to be pedantic but it is fuel after all.

Because it's the only line that's leaking...

[gordner]

Right now, though it is just about a certainty one of the others will be soon...if it is the hard line area that is leaking it is most likely a corrosion issue, maybe abetted by chaffing or more likely dissimilar metal at a clamp location. All the lines are the same material most likely, in the same location and conditions. If you fix the one it will be good practice for doing the others though...

[gordner]

What year is your Subaru? Have you researched recalls?

[gordner]

I did run a Chevy cavalier for about a year and a half bypassing the factory lines from the tank all the way to the firewall with no issues so I don't see any safety issue with your plan, as long as you route the line sensibly and secure it well.

[Hydrocket]

Originally Posted by gordner

What year is your Subaru? Have you researched recalls?

Recalls? It's a 1998

I'd be surprised if there were any.

[Tilikum Turbo]

Originally Posted by Hydrocket

Because it's the only line that's leaking...

If you gave this car to a mechanic, and he told you what you proposing as a fix, that he was going to do that...would you give the green light? I would look at the guy and say...are you ****** crazy? Do it RIGHT...this is gasoline, not orange juice running thru these lines.

VERY prudent to do the other rubber lines while your there...everyone of those is suspect at this point with all that salt, etc, and maybe even spray a little clear-coat afterwards to keep that salt at bay(or slow down the process of corrosion)

[Hydrocket]

Originally Posted by Tilikum Turbo

If you gave this car to a mechanic, and he told you what you proposing as a fix, that he was going to do that...would you give the green light?

Actually, my mechanic texted me not too long ago, and he said it's not a problem.

However, he did say it would be a problem for him if it was the high pressure/feed line.

[Nostril Cheese]

Originally Posted by Tilikum Turbo

If you gave this car to a mechanic, and he told you what you proposing as a fix, that he was going to do that...would you give the green light? I would look at the guy and say...are you ****** crazy? Do it RIGHT...this is gasoline, not orange juice running thru these lines.

A guy from Los Angeles commenting on a fix for a beater in Ontario, Canada.

[fastfredracing]

I found that amusing also. Your idea will work fine . Id also get the correct style high pressure clamps . You will more likely than not, damage other lines in the process, so be prepared to open up a small can of worms, and have supplies on standby to repair the pressure, and vapor lines .

[Tobra]

Originally Posted by sc_rufctr

You're welcome but how do you know the return line is the only line with any issues?

I don't mean to be pedantic but it is fuel after all.

All the lines are bad, or soon will be. If you just do that one, keep a fire extinguisher in the car.

Coolant hoses are probably suspect if they are the OG stuff too.

[1990C4S]

I suspect he will have a very low chance of a fire. In Windsor. In winter. It will be covered in wet salty water 90% of the time....

[gshase]

Check RE-Calls I had a 05 and remember something about corrosion and leaky fuel lines being Re called

[RANDY P]

I know it sux, but if you're planning on keeping it, drop the tank. Reason being the others aren't far behind, the one you're fixing is just the 1st one across the finish line. You will have to address it soon, and probably start another leak somewhere else touching it anyhow.

Unless, cars rust differently in CA vs USA

rjp

[gordner]

I went through the recalls and nothing helps him there, the only fuel line recall was on the legacy and outback models in 2003 or somehting.