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I have a 98 Ultra classic, and the return fuel line has so much pressure on it that it has been blowing itself out of the quick disconnect. is there supposed to be that much pressure on that line?

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This sounds like a bad fuel pressure regulator, perhaps the fuel lines need new o rings or just to be replaced if changing the i ring isn't possible. I'm including a link, read up and see what applies to your bike. This should get you headed in the right direction!
I have a 98 Ultra classic, and the return fuel lin - 59910876-26b2-45bd-9d18-8d1e6bae6f62-nm0tiheo3ogpzf5c4h5wl1la-3-0.jpeg

I have a 98 Ultra classic, and the return fuel lin - 0be83fb8-c991-450f-a083-a0b41e626116-nm0tiheo3ogpzf5c4h5wl1la-3-5.jpegiheo3ogpzf5c4h5wl1la-3-5.jpeg" alt="0be83fb8-c991-450f-a083-a0b41e626116-nm0tiheo3oI have a 98 Ultra classic, and the return fuel lin - 6eadc9df-a5b8-4a5d-9c6c-960b8c92490e-nm0tiheo3ogpzf5c4h5wl1la-3-9.jpegoads/images/6eadc9df-a5b8-4a5d-9c6c-960b8c92490e-nm0tiheo3ogpzf5c4h5wl1la-3-9.jpeg" alt="6eadc9df-a5b8-4a5d-9c6c-960b8c92490e-nm0tiheo3ogpzf5c4h5wl1la-3-9.jpeg" class="h_mi" />

Posted on Feb 28, 2019


6 Suggested Answers


6ya staff

  • 2 Answers


Hi there,
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Posted on Jan 02, 2017


Ronnie Houston

  • 2920 Answers

SOURCE: remove fuel lines from tank (quick disconnect) 2006 f-250 diesel

yes there are 2 lines the feed line and the return line

Posted on Dec 06, 2008


  • 508 Answers

SOURCE: fuel filter to tank quick disconnect broken

Here is a quick solution. Go to Napa Auto Parts with your line size. Take the piece you broke off so they can match the line size. They sell pieces that are about 18 inches long so you can splice it in. These pieces range in price from about 16 to 22 dollars. Other parts stores don't carry this fuel line. They will want to sell you the whole line at a cost of hundreds of dollars. Napa will be able to accomodate your request as I know because I get these pieces from them often.
Good luck. Let me know how it goes. Just read the directions on the package. You need to heat the line up to in stall.

Posted on Feb 26, 2009


Clint Smock

  • 4669 Answers

SOURCE: fuel pressure regulator

Have you checked the fuel pressure? If it is high and fuel is not returning, the regulator is bad. If it is low and fuel is not returning, the pump is bad.

Posted on Mar 11, 2009


Rob Stephenson

  • 284 Answers

SOURCE: Engine light on/off sporadically while riding.

You don't have that on a 2002. Do you have a power commander on it? Sounds typical of the older style power commander ( IIIr ) one thing to pay attention to is does it do it under load? If it's not showing any historic codes and the bike rides fine, and you have a power commander 3r I wouldn't worry. It's normal. The older power commander lies to the ecm. Sometimes it gets confused and kind of glitches ( that's where the light comes from ) but if it has running issues to I would take it to a shop to find out what the codes are and go from there.

I’m happy to assist further over the phone at

Posted on Jun 27, 2009


  • 344 Answers

SOURCE: 95 2.5 jeep wrangler stalls consistantly and will

I had the same issue with my 4.0, I went through all the same BS you did and in the end it was a faulty fuel pump. Pricy i know but im sure thats your problem

Posted on Nov 15, 2009

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The fuel pressure should be 49 psi. On all engines except the 3.0 liter you can check the fuel pressure at the fuel pressure test port located on the fuel rail. On the 3.0 liter engine you can disconnect the quick-connect fuel line fitting at the fuel rail and install a fuel gauge with a (T) fitting and adapters to check fuel pressure. Start the engine and check the fuel pressure. Hope this will help.

May 24, 2010 | 1998 Dodge Caravan

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My 1990 chrysler imperial will idle fine but it dies when you give it gas.I changed the fuel pump and both computers and i'm still having the problem.

Sounds as though it may be your fuel pressure regulator. Easy fix and you can troubleshoot it easily also. Check the fuel pressure first. This is your part....

Fig. 13: Compression gauge and a combination vacuum/fuel pressure test gauge

TESTING Except Premier and Monaco NOTE: To perform this test, you will need a pressure gauge capable of reading pressures above 55 psi (379 kPa). The gauge must have a connection that will fit the fuel rail service valve. The gauge must be the equivalent of Chrysler pressure gauge No. C-4799 and the connector fitting compatible with pressure test adapter 6539. You may also need a T and the fittings necessary to connect the gauge into the fuel supply line at the tank, as well as a 2 gallon container suitable for collecting fuel.
  1. Release the fuel system pressure as described in Section 1.
  2. Disconnect and plug the vacuum line going to the fuel pressure regulator.
  3. Remove fuel hose quick connector from the chassis line.
  4. Install the adapter between the fuel supply hose and chassis fuel line assembly for the 3.0L engines or into the service port of the fuel rail for 3.3L and 3.8L engines.
  5. Hold the gauge and have someone start the engine. Run the engine at idle speed in Neutral (manual transaxles) or Park (automatic transaxles). CAUTION
    Exercise extreme caution while under the hood with the engine running. Keep clear of all moving belts, fans, exhaust manifolds, etc.
  6. Read the pressure. It should be 48 psi (330 kPa). If it is outside the range, take note of it.
  7. Stop the engine.
  8. Once again depressurize the system, disconnect the gauge and replace the protective cover.
  9. If the pressure was correct, the test is complete. If the pressure is below the range, proceed with the next step; if it is too high, skip to Step 13. WARNING
    In the next step, note that fuel may drain from the lines as you disconnect them. Make sure all surrounding exhaust system parts are cool and that all sources of ignition are removed from the area. Collect fuel and dispose of it safely.
  10. Connect the gauge into the fuel supply line running between the tank and the filter which is located at the rear of the vehicle. WARNING
    Make sure all connections are secure.
  11. Have an assistant start the engine, then read the pressure gauge. If the pressure has risen more than 5 psi (35 kPa), replace the filter. If the pressure is now within range, allow the engine to cool and remove all sources of ignition; depressurize the system; disconnect the gauge from the lines; replace the fuel filter; and restore all connections.
  12. If the pressure is still too low, gently and gradually pinch the fuel return line closed as you watch the gauge. If the pressure increases, the fuel pressure regulator is at fault. If there is no change, the problem is either clogging of the filter sock mounted on the pump or a defective pump itself.
  13. If the pressure is too high, follow this procedure:
    1. Shut off the engine and allow it to cool.
    2. Depressurize the fuel system, then disconnect the fuel return hose at the chassis, near the fuel tank.
    3. Connect a 3 ft. (91cm) length of hose to the open end of the line running along the chassis. Position the open end of the line into a container suitable for collecting fuel.
    4. Have a helper start the engine, then check the pressure again. If it is now correct, check the in-tank fuel return hose for kinking.
    5. If the in-tank fuel return hose is okay, and the system still exhibits excessive pressure with the tank half full or more, the fuel pump reservoir check valve or aspirator jet may be obstructed and the assembly must be replaced.
  14. If the pressure is still too high, perform the following:
    1. Shut the engine OFF, and allow it to cool.
    2. Depressurize the system once again and reconnect the fuel lines at the rear.
    3. Disconnect the fuel return hose at the pressure regulator. Collect all fuel that drains.
    4. Run the open connection into a large metal container.
    5. Reconnect the fuel gauge to the fuel rail.
    6. Start the engine and repeat the test. If the fuel pressure is now correct, clean a clogged return line or replace pinched or kinked sections of the return line. If no such problems exist, replace the fuel pressure regulator.
Premier and Monaco CAUTION
Wear eye protection when servicing the fuel system. Do not smoke or allow open flame near fuel system components during fuel system service.
  1. Remove the fuel tank filler cap to relieve the fuel tank pressure. NOTE: System fuel pressure will be released when disconnecting the fuel supply tube. Have shop towels handy to absorb spilled fuel.
  2. Use the quick disconnect tool 6182, or equivalent, to remove the black fuel supply tube from the fuel rail. Slide the tool over the nipple and up into the connector until the handle fits the connector. Pull the fuel supply tube off the fuel rail.
  3. Install the fuel tube pressure adapter tool 6175, or equivalent.
  4. Push the female end with the quick-connect fitting over the fuel rail until a click is heard. Pull the connector back to ensure that it is locked in place.
  5. Push the male end with the nipple into the black fuel supply tube until a click is heard. Pull the nipple back to ensure that it is locked in place.
  6. Attach a 0–60 psi (0–415 kPa) gauge from the fuel pressure test kit 5069, or equivalent, to the port on the fuel tube pressure adapter tool.
  7. Start the engine and check the fuel pressure. It should be 28–30 psi (193–207 kPa) for early models and 43 psi (300 kPa) for late models. The fuel pressure regulator on these vehicles is non-adjustable.
  8. If the fuel pressure is low, check for fuel flow through the return tube.
    1. If fuel is returning to the fuel tank through the fuel return tube, replace the fuel pressure regulator with a new one.
    2. If the fuel is not returning to the fuel tank or just trickling out, inspect for a faulty fuel pump, possible clogged fuel filter or other restriction between the fuel pressure regulator and the fuel pump.
  9. If the fuel pressure is high, check the pressure regulator vacuum hose for leaks, and for a kink or restriction in the fuel return hose. If the pressure regulator vacuum hose is not leaking, the return tube is not kinked and does not have a restriction, the fuel pressure regulator should be replaced with a new one.
  10. Remove the pressure gauge.
  11. Disconnect the fuel tube pressure adapter tool with the quick disconnect tool.
  12. Prior to installing the fuel tubes to the regulator and fuel rail the tube ends must be lightly lubricated with clean SAE 30 weight engine oil. Refer to the procedures describing the removal and installation of the fuel tubes.
  13. Install the black fuel supply tube to the fuel rail and the gray fuel return tube to the pressure regulator.
  14. Install the fuel tank filler cap.
  15. Start the vehicle and check for fuel leaks. NOTE: When starting the engine, allow extra time for the system to pressurize itself.

Oct 06, 2009 | 1990 Chrysler Imperial

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