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97 Mercury Mystique has leak in plastic gas return line
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blt
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Mar 7, 2011, 9:54 PM
Post #1 of 13
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97 Mercury Mystique has leak in plastic gas return line
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The 5/16 line is in an exposed spot next to the tank and has a pinhole leak and probably was hit by road debree. Can't drive as it's under some pressure.
I was surprised to find out it was plastic! Service manual says to repair with 2 barb connectors and heat plastic with boiling water. (not very practical) as it goes into the top of the tank.
Any ideas on repairing this?
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Hammer Time
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Mar 8, 2011, 5:27 AM
Post #2 of 13
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Re: 97 Mercury Mystique has leak in plastic gas return line
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If you can't access the line, then you just have to remove the tank in order to gain access. Nobody ever said this job was easy.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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re-tired
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Mar 8, 2011, 9:33 AM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Hammer is quite right when he says it's not easy. Depending on fuel level the tank can weigh well over a hundred pounds. However you say the damaged area is next to tank . I believe that NAPA sells a line repair kit that uses special crimp style clamps with the barbed connector . I've used them several timnes and never had a failure.
LIFE'S SHORT GO FISH
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Hammer Time
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Mar 8, 2011, 10:41 AM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Yes, Dormon makes a kit that costs about $225 but if you only have one to fix, it's not real practical but if you find a shop that already has one, it will be easiest to just let them repair it for you.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
(This post was edited by Hammer Time on Mar 8, 2011, 10:42 AM)
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re-tired
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Mar 8, 2011, 6:11 PM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Dorman 800-064 will get him just the splice kit for around $16.00
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LIFE'S SHORT GO FISH
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Hammer Time
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Mar 8, 2011, 6:18 PM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Might be hard to do without the pliers/clamps that squeeze them together though.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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re-tired
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Mar 8, 2011, 8:35 PM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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OK The special crimp pliers ......$49.00
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Special clamps $8.00
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Grand total 75.00 ....Whata you mean a shop will do it fo $50.00 ? OH well it was the principle of the thing . 
LIFE'S SHORT GO FISH
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Hammer Time
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Mar 8, 2011, 8:52 PM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Hahaha...........RT, that's not what i meant.
The special pliers that clamp onto the hose and pull it over the barbs. I don't see how you can do it without it, even with heat.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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re-tired
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Mar 8, 2011, 10:05 PM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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I managed to do a bunch. Held the splicer at center with needle nose v grips , just snug enough not to distort.Heat splice with micro torch , just right . Lube line and Ram in.Took 2 tries 1 out of 10...................... NOTE: DO NOT ATTEMPT AT HOME , I ARE A PROFESHINAL .
LIFE'S SHORT GO FISH
(This post was edited by re-tired on Mar 9, 2011, 7:49 AM)
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blt
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Mar 8, 2011, 10:08 PM
Post #10 of 13
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Re: 97 Mercury Mystique has leak in plastic gas return line
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I purchased the Dorman 5/16 line and 2 barbs kit early today and there is no way you can heat the tubing and slide the barbs in far enough by hand. Only got it in 2 out of the five barbs and that was doing one end in the house using boiling water. Of course the parts store didn't know you need a special tool to pull the lines together over the barbs, nor I until seeing these posts late tonight. To use that tool, you would have to disconnect the lines and take them out of the car which means you can't do that without dropping the tank anyway.
This was a waste today, I'll try another solution.
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Hammer Time
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Mar 9, 2011, 6:06 AM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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If you have an air blower type heat gun you may be able to push it on further but you have to be very careful with it because a little too much heat and the line will just fold and kink and you start over. Concentrate the heat on the part touching the barb and not further up the hose. You need to keep that part rigid enough to push. Wear gloves as the barb will get hot.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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re-tired
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Mar 9, 2011, 7:59 AM
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Blt, do as HT has suggested to complete the barb install .As he said , be careful not to heat the line too much , you dont want to kink. Heating the barb also seems to help. I am getting out of the way. As they say , " to many cooks".....
LIFE'S SHORT GO FISH
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blt
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Mar 9, 2011, 10:45 PM
Post #13 of 13
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Re: 97 Mercury Mystique has leak in plastic gas return line
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Thanks guys for your input. I ended up doing it the old fashioned way. This is a return line with little pressure so I cut out 3/8" of damaged line and took 1/4 inch non fuel injection gas line which has more stretch and prestretched both ends of a very short piece over 2 pieces of the same 5/16" plastic tube.
After awhile I quickly transfered the hose to the tubing under the car for a very tight seal. Finished off with 2 clamps.
Should last longer than the car.
BLT
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