Tools Required

• AN wrench set
• Bench vise
• Hose cutter or fine-tooth hacksaw
• Deburring tool
• Marker
• Assembly lubricant
• Safety glasses
• Fuel-resistant gloves

Pre-Installation Checklist

• Confirm whether the supplied hose is CPE, PTFE, or antistatic PTFE and use the matching assembly method.
• Plan the routing path away from exhaust heat, moving parts, sharp edges, and abrasion points.
• Confirm the correct hose ends and AN fittings are available.
• Wear safety glasses and fuel-resistant gloves and work away from ignition sources.

Installation Steps

1. Measure the hose along the intended routing path and allow enough length for bends without kinks or tension.
2. Wrap the cutting area with tape, make a square cut, then deburr and clean the hose end.
3. For CPE hose, secure the socket in a vise, thread the hose into it until snug, leave a 1-1.5 mm gap, and mark the hose position.
4. For PTFE hose, slide on the socket, flare back the outer braid, seat the ferrule fully on the PTFE liner with no gap, and push the assembly onto the nipple.
5. Apply assembly lubricant to the fitting threads, hold the socket securely, and tighten the fitting body until fully seated.
6. Clean and pressure-test the completed hose assembly before installing it.
7. Install the hose according to the system flow diagram and secure it away from heat, sharp edges, and moving parts.

Post-Installation Verification

• Verify all hose ends are fully seated and fittings are secure without overtightening.
• Confirm no hose is kinked, twisted, under tension, or exposed to abrasion or excessive heat.
• Pressure-test the assembly and inspect every connection for leaks before starting the engine.
• Reinspect after the road test and after 50-100 km.

Troubleshooting

• Fuel leak: turn the ignition OFF immediately and replace damaged hose or fittings before operation.
• Restricted flow or low pressure: inspect for kinks, incorrect routing, debris, or an incomplete hose-end assembly.
• Air entering the system or fluctuating pressure: check all hose ends and fittings for loose connections or leaks.

Maintenance

• Inspect hose routing, abrasion protection, and fittings periodically.
• Replace any hose that is damaged, leaking, kinked, or heat-affected before operating the vehicle.

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