Fuel Line (return) replacement -what to use

[clean96XJ]

1996 XJ 4 door. 4.0

Return fuel line is super brittle.

What is the suggested replacement?

Use brake line and bend it?
or soft line?

Searched and found very little.

Thanks all

 

[RCP Phx]

Metal line gives more physical protection but takes a lot of work. Soft line will get it done in minutes!

 

[Runnin'OnEmpty]

A 1996 XJ doesn't have a return fuel line.
The plastic line you're seeing must be a
vapor return line from the fuel tank.

Since there's very low vapor pressure involved,
you can use just about anything you wish; metal,
rubber, plastic, etc.

There's a metal line called NICop that's a blend of
nickle and copper that is easy to bend. Or you can
just pick up a roll of plastic line...

 

[Unclewolverine]

I thought 96 still had one, wasn't 97 the first year for the stupid return less system? I took him saying it was brittle as it was rusty. Use metal brake line for the straight parts rubber fuel line for the bendy parts.

 

[Anak]

No return line on a '96.

That is part of what makes the '96 sending unit so unique. The other issue being the presence on the FP regulator on the sending unit assy.

Runnin'OnEmpty is spot on. Vapor line is probably what is in play.

 

[clean96XJ]

Thanks all !

vapor return line

It's the front to rear thin metal line runs right next to brake line and bigger fuel line.

Taking NICop option

 

[Unclewolverine]

Dang weird 96s. Glad I got a 95.

 

[Runnin'OnEmpty]

Dang weird 96s........

You got that right. I bought my 96 without knowing
what a red-headed stepchild they were.

By the way, there were more 96s sold than any other
model year of XJ.