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Print in friendly format Send this term to a friend  4L60E
1994-1996, the 4L60 with Electronic Control. From what I have seen, it seems a bit more durable....
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CorvetteBob Did a fuel line swap on the 89
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Well, Saturday I started the fuel line swap in the early afternoon. Worked until about 11:30pm. It’s odd that even though you’ve tried to think it through and look at how and why you’re gonna do things, you still spend a good amount of time in the head scratcher mode making sure it’s all gonna go how you want. I decided to use an line for the ease of flexibility it offers. I was VERY close to going with a NiCopp type line, but if I had, I’d still be trying to work it over the batwing. So with two twenty foot rolls of -6 Aeroquip and a predetermined group of fittings on hand, I set about slicing and dicing sections of old line (rusted inside) while finding ways to rout the lines thru the original path, but also ways to utilize the original clamping spots, but also finding spots to create mounting points to avoid shaking and vibration damage.
So to finish the story so far, I have it back up to the break at the filter. The original had a break in the return line there also, but I’ll probably just run a straight shot from the regulator to the tank. If that’s a bad idea, don’t be afraid to say so.
I used 13 feet from the tank to the filter, plus about 7-8 inches for rubber line (F.I.rated) off the tank to the first -an fitting. There may be some rethinking on one or two of the item, but it’s pretty much in.
All in all, it wasn’t the worst job I’ve ever done on a car. Putting the engine and then the tranny in by myself was much more taxing.
Posted on: 2020/9/7 23:50
Edited by CorvetteBob on 2020/9/8 0:06:02
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joeld Re: Did a fuel line swap on the 89
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Good job on that project. Got any sore shoulders? Was the rust inside the lines or just externally. Are you replacing from fuel filter to rail also. This is what I've thought about doing for years to eliminate those old rubber lines.
Posted on: 2020/9/8 3:39
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CorvetteBob Re: Did a fuel line swap on the 89
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Well, yes, yes, and yes.
Shoulders were sore at the end of the night. Ibuprofen took care of that thru the magic of modern chemistry.

The rust WAS on the inside of the lines. The car has been inactive for 15 years. I tried in April to de-rust the lines, but was never really sure of my success. Eventually, my OCD got the better of me. In cutting out the old lines, I did see rust within some sections. So now I hope to “sleep” a little better.

Finally, yes, I’m replacing the lines in their entirety. However I should tell you that there are still some rubber lines. The hose connections at the tank are FAR too short to place a compression fitting on, there’s NO room to to flare them even if long enough. The practical option I took was to get injection rated rubber hose and connect them to “hose barb to -6 an adapters less than a foot away.
If you REALLY, REALLY want to connect directly to an “an” hose Fitting directly from the tank, you’d need to take the pump mounting assembly out and go to a metal fab shop and have them remove the old lines coming out the top, and put in the desired style lines that offer the clearance and length desired. It would probably be to your advantage to have the New lines With you, as well as the fitting hardware needed already on the new lines if they are the kind that need to be behind the flare you use. My approach would be to use a hard tube to an fitting adapter, and leave the hard lines unflared.
Posted on: 2020/9/8 4:07
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Matatk Re: Did a fuel line swap on the 89
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Good to hear it's coming along. Post some pictures if you took any.
Posted on: 2020/9/8 4:10
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CorvetteBob Re: Did a fuel line swap on the 89
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I was pretty filthy to be picking up my phone for pics, but I’ll try to snap a few and see how they come out.
I might add, I didn’t need to remove the rear bumper cover. I worked thru the right side taillight holes and also took off the right rear wheel and the inner wheel well and had great access to what I was doing. I also used a “fish” wire hooked to the front end of the hoses to work them thru tight areas and over the batwing. At one point, as I was working the new lines over the rear crossmember, and toward the batwing, I looked and saw myself looking as if I was wrestling with stainless steel snakes.
I will say, having my car on the KwikLift was a big, big part of this job going as well as it did.
Posted on: 2020/9/8 4:24
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CorvetteBob Re: Did a fuel line swap on the 89
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I’ll try to post pics of the new lines.
This is coming off the tank, and where I glued a clamp to the right rear speaker box to help it with stability.

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jpeg  A78A175E-92ED-478B-8AA3-18424793ED6C.jpeg (57.24 KB)
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Posted on: 2020/9/16 16:00
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CorvetteBob Re: Did a fuel line swap on the 89
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This is where it comes out in front of the tank and between the tank and cross member, then snakes outside the spare tire mount to start over the sway bar, and then over the batwing and on up inside the wheel well, between the frame and storage compartment.

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jpeg  F2A6EA80-658C-4C3F-AD09-888F66D7122B.jpeg (234.20 KB)
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Posted on: 2020/9/16 16:07
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CorvetteBob Re: Did a fuel line swap on the 89
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It’s a little hard to see, but here’s where it goes past the right rear shock.

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jpeg  01B8568A-D55A-4B9E-BB8F-3DB760741B85.jpeg (155.11 KB)
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Posted on: 2020/9/16 16:09
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CorvetteBob Re: Did a fuel line swap on the 89
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This is where the lines drop out in front of the wheel and start the transition to run up the passenger side. The screw head you see in a self drilling #10. I’ll be replacing this soon with a machine screw from the inside, behind the seat.

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jpeg  1937611A-D4A0-40B3-9A1C-7E9476900AF6.jpeg (283.65 KB)
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Posted on: 2020/9/16 16:14
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CorvetteBob Re: Did a fuel line swap on the 89
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From in front of the rear wheel, looking forward along the side.

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jpeg  0F1AE4CB-A525-430A-8BD9-4EE505B7017F.jpeg (285.55 KB)
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Posted on: 2020/9/16 16:20
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CorvetteBob Re: Did a fuel line swap on the 89
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The filter. This is from Summit. It’s a 10 micron filter that comes with the quick connect fittings to adapt to -6 an lines. I used a 45* to angle the line up toward the engine. The return line is clamped above and has no connector like the OEM , but rather is a straight run from the tank to the regulator.

Laugh all you want. I need the arrow.

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Posted on: 2020/9/16 16:27
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CorvetteBob Re: Did a fuel line swap on the 89
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Finally, here’s where it comes up past the header. The black bar at the top of the pic is the rear ac compressor support rod.
I have the lines clamped to the frame before and after the angular frame support to hold it still.
From here it’ll route to the block at the mechanical pump location, them up the front of the engine like OEM routing.
So there you have it. Whaddya think? I’m also open to alternative suggestions.

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Posted on: 2020/9/16 16:37
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joeld Re: Did a fuel line swap on the 89
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That is a very neat and well thought out job. Clamps looks good, line looks firmly secured. And arrows are our friends!
Posted on: 2020/9/16 18:49
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CorvetteBob Re: Did a fuel line swap on the 89
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Thanks! I appreciate the comments very much!
Posted on: 2020/9/16 19:26
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CorvetteBob Re: Did a fuel line swap on the 89
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As for the clamping of the hoses, I made the ones that are aluminum. The black Anodized ones I bought off ebay from a Chinese “ship from US” source. But all the strap type, both aluminum and aluminum with black rubber were the ones I made.
Posted on: 2020/9/16 20:21
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hcbph Re: Did a fuel line swap on the 89
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looks pretty good to me. Have to keep this in mind if I ever have to do this. Thanks for sharing.
Posted on: 2020/10/1 1:43
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j3studio Re: Did a fuel line swap on the 89
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Nice work!

Posted on: 2020/10/2 17:10
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CorvetteBob Re: Did a fuel line swap on the 89
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Thanks guys!
Posted on: 2020/10/3 0:06
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bogus Re: Did a fuel line swap on the 89
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looks great!!!!!!
Posted on: 2020/10/3 17:21
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