Foretravel Owners' Forum For owners and Fans of Foretravel Motorcoaches September 23, 2025 ...

Third step to Fuel Line Replacement (Pulling new Lines)

May 05, 2014, 10:42:20 pm

Remove channel cover in storage bay.

    •   Remove 5 screws from wooden back channel and remove.
    •   Remove screws from the fiberglass  channel and remove.  Takes a little maneuvering to get out.
    •   Put support under to take stress off hoses and wires.  There are soooo many lines in this channel because of the aqua hot.

Replace main fuel line to engine.
    •   Disconnect fuel line from filter with two one inch wrenches. This is the 5/8 inch line going to the center of the tank.  Be
          careful as the line is full of fuel.
    •   Remove flair fitting from the tank side of the fuel line and connect to the new fuel line using  a brass barbed connector, then
          wrap with electrical tape for a smooth transition.
    •   Pull from tank area to center bay, then from center bay to he rear axle then from there to the fuel filter.  Last bulk head
          is the hardest.  Take your time and don't force it.  Had to spray with silicone spray to get through last bulkhead.

Replace return line from the tank to the fuel cooler.
    •   Remove radiator grill by drilling out the 6 pop rivets.
    •   Remove fuel line from outlet side of the fuel cooler and drain line.  This is the ½ inch line that goes to the far left  fitting on
          passenger side of tank.  This connection was hard to remove and required some penetrating oil.
    •   Remove flair fitting from the tank side of the fuel line and connect the new fuel line using  a brass barbed connector.  Wrap
          with electrical tape for a smooth transition.
    •   Put wire ties on any bundles that need to be cut to allow you to pull line through.  This way when you cut the wire tie they
          stay together and can be retightened when done.  There are lots of wire ties and some are very tight and very difficult to
          get at.  It was very tempting to not replace the return line because of this. 
    •   Replace fitting on new line.  This required inserting the end of the new line a pan of boiling water and then pushing in the
          fitting.
    •   This line was very difficult to pull because of all the wire tied bundles.

Replace generator and aqua hot lines using the same procedure.
    •  Aqua Hot filter required a lot of extra fuel line because of the filter being in the front drivers side bay.  You have to pull a   
          line from the tank to the front and then from the front back to the aqua hot.
    •  On hard to pull lines I sprayed the new line with silicone spray and the old line as I pulled from compartment to
          compartment.

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #1 – May 05, 2014, 11:59:41 pm

Hi Jason,
  Good work. Thanks again for the pictures. The pictures show the amount of work involved.
Raymond

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #2 – May 06, 2014, 12:16:12 am

 Just reading your report on lubing the lines to pull thru and wondered if a person was to coat the new and old tube with "wire pulling grease" yellow stuff. Should work better I would think as it is made for this kind of job.
JohnH

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #3 – May 06, 2014, 06:57:04 am

I am glad I had FT do mine. Not high tech but a lot of work.  Great writeup and great that you are doing it too.

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #4 – May 06, 2014, 07:11:14 am

Raymond:
This was an incredible amount of work pulling the lines through all the bundles that were so tightly bound by wire ties as well as metal straps.  Some of the bolts that hold the metal straps to the frame are very hard to reach and if removed are almost impossible to replace.

John:
Great idea and would help pulling the new line.  The old line in the bundle is the hardest to get moving.  There are  bundles of electric wires includes in the bundle and am not sure if any of the chemicals in the compound would create a problem.

Thanks
Jason

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #5 – May 06, 2014, 11:01:26 am

 That stuff is exactly one of the reasons for me saying to use it as it is inert to wiring, made for that job and it really works smooth too believe me.
JohnH

Quote Selected

Re: Third step to Fuel Line Replacement (Pulling new Lines)

Reply #6 – May 06, 2014, 11:53:22 am

This is what John is talking about.
http://www.idealindustries.com/products/wire_installation/lubricants/yellow_77.jsp

Quote Selected