I just bought a 91 tracker, the po told me the pump hanger was leaking...I was disturbed to find that just the hanger is $160, so I decide to drop the tank and have a look.  At the time I was real happy to see the hanger was fine, it was the hose that went from the tank to the fuel filter that was cracked....YAY....then I call around, not available from part stores, call the dealer.....2 weeks to get it in and $90!!!!  I brought it to a machine shop today to see if they could build me one, but they dont have the metric (14mm) ends. 

There must be another car that uses the same line, 14mm male flared to banjo fitting.  Does anybody know of a suitable replacement or where I could get one faster...and cheaper?

THanks
Fred

Take it to a hose store, they will take the ends off, and put a new hose on it
for about $~20 depending on the length, there is several of those stores here
called hose man, hose mart and hose and air supply, so look for something
that is similar

Wild

THanks wild, I tried a few places here that sell hydraulic hose, but the problem is that they dont carry the metric fittings.  I cant just replace the hose beciase it is the steel line part that broke, almost inside the male fitting.  I wonder if these hoses might be the same as some other Suzuki cars...there must be an alternative.

Post a pic of the problem, lets see if there are some ideas that can solve the problem,
or call Hawk's Suzuki Parts and ask for a good used one

OK, here of some pics of the offending hose.  You can see where the metal tube is broken.  The threaded metal end goes into the pickup tube of the pump mount on the tank, the banjo fitting goes on the fuel filter.  I was looking today in AN fittings, but my biggest concern about anything custom is the seal it will make on the male end.  The metal hose goes through the fitting and is flared at the end, is this flare what causes the system to seal, or if I can getting some other 14mm 1.5 fitting that scres in there that mounts directly to a hose will the threads themselves keep it from leaking.  As my first issue with my first trackkick...I am off to a bad start.

Well I thought I would be smark and call the Suzuki dealer instead of the Chev one to see what they had.  They can get it (5 days) but instead of the $90 I thought was too much from Chev, theirs is $167!

It looks like the 14mm 1.5 fitting is double flared and basically the same as a brake line, I am going to check the car parts store this afternoon, maybe I can get a brake line that will fit in and then just find the best way to attach that to the rubber hose.

Well I thought I would be smark and call the Suzuki dealer instead of the Chev one to see what they had.  They can get it (5 days) but instead of the $90 I thought was too much from Chev, theirs is $167!

It looks like the 14mm 1.5 fitting is double flared and basically the same as a brake line, I am going to check the car parts store this afternoon, maybe I can get a brake line that will fit in and then just find the best way to attach that to the rubber hose.

if 90 bucks is too much head for a wrecking yard. or if you want new, call Duncan at power Suzuki in Salem or. tell him your calling from a zukiworld referral.

the banjo end is the easy part, its a common metric size. the flare and thread pitch on the nut end is where I had problems with my swap.(no body I could find has it).

If you find a brake fitting works, you could braze the tube or a tube to the fitting then the
hose guys can use that to attach the hose section. They might even do the brazing for you
or show them what you have in mind to see if they can make it work

Wild

Well I just got back from carquest.  I bought a 12 5/16 (have to double check that) fuel line with the standard brake nuts and double flared at each end.  I am going to take my old 14mm nut, punch out the old tube, cut this new tube in half and slide it into the 14mm nut.  That should give me the double flared end of tube, the 14mm nut on it, and a few inches to tube sticking out behind it.  I'll then cut the rubber hose off behind the broken crimped end, slide in the new tube and double clamp it with high pressure clamps.  Crossing my fingers that this works.  Will post pictures if it does.  NOTE TO EVERYBODY...what ever you do, find a way to save the 14mm fitting, as the guy at the parts counter said 'they are rare as hens teeth"

The fuel system runs at 36 PSI, at least on the 8V engine, could be 43 PSI
on a 16V I don't remember, but you should not have any trouble with the
clamps holding the pressure

Wild

OK, so here is what I ended up doing.

1- Soak the male end in rust lubricant stuff.

2- Take the original 14mm male end and grind down the side where the tube comes out, going towards the filter

3- Once you can see the old tube well in the fitting, either push it out...or if you can't, like in my case, drill it out.

4- Take the fuel line you bought and cut it in half, you now have a double flared metal tube that will fit into the 14mm male fitting and also into the rubber hose on the other side.

5- Slide the tube into the male fitting and then into the hose.  I was going to put a barb on the end going into the hose for better sealing, but it is already a really tight fit.  Put on your fuel pressure hose clamps..not regular clamps. I also left the spring covering on the metal tube for no real reason than it looked cooler and it might provide some additional protection.

6- wire brush ends, paint and clean hoses.

I know this may not have been a very exciting write up, and I probably went into too much detail, but I figure if it can help someone by saving $100 + dollars on this hose, or get them out of a pinch when they cant get the part it might be worth it.  Total cost : $5 for the brake line and $2 for the clamps.

THanks for all the replys and the help, now I just cross my fingers that it will work, will let you know in a week or so.