Dorman 800-057 5/16 Inch Quick Connector Instruction Manual

1. Introduction

The Dorman 800-057 5/16 Inch Quick Connector is a direct replacement component designed for repairing damaged fuel line connectors. This part allows for the replacement of only the affected connector, rather than the entire fuel line assembly, offering a cost-effective and efficient repair solution. It is engineered to provide a precise fit and reliable, leak-free performance under various underhood conditions.

Key Features:

• Direct Replacement: Designed to fit and function identically to the vehicle's original equipment.
• Quality Construction: Manufactured from premium materials for extended service life.
• Cost-Effective: Enables replacement of only the damaged part, avoiding the need for a complete assembly replacement.

2. Components Included

The Dorman 800-057 package typically includes:

• Dorman 5/16 Inch Quick Connector(s)
• 18 Inches of 5/16 Inch Nylon Tube
• Union Compatible with Select Models

Image 1: Dorman 800-057 5/16 Inch Quick Connector with included nylon tube.

3. Setup and Preparation

Before beginning the installation, ensure you have the necessary tools, including a tubing cutter, a heat gun, and the Dorman fuel line repair tool (if using a repair kit). Always confirm vehicle compatibility using the manufacturer's fitment guide.

3.1 Safety Precautions

• Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle's fuel system is depressurized before working on fuel lines.
• Work in a well-ventilated area and keep fire extinguishers nearby.
• Refer to your vehicle's service manual for specific fuel system procedures.

3.2 Measuring and Cutting Tubing

1. Measure the required length of the 5/16 inch nylon tubing for your repair.
2. Use a specialized tubing cutter to make a clean, straight cut. Avoid using knives or shears that may deform the tubing.

4. Operating Instructions (Attaching Connectors)

The following steps detail how to attach the Dorman 800-057 Quick Connector to the nylon tubing using the Dorman fuel line repair tool and a heat gun. These steps are generally applicable to various Dorman quick connectors.

4.1 Attaching Holding Plates and Connector to Tool

1. Attach the holding plates to the new nylon tubing using the tightening screws on the Dorman repair tool. Ensure the tubing is securely held.
2. Attach the desired quick connector (e.g., straight, 90-degree, 45-degree) to the appropriate adapter on the repair tool assembly.

4.2 Clamping the Connector onto the Line

1. Position the repair tool so that the connector is aligned with the end of the nylon tubing.
2. Using a heat gun, gently warm the end of the nylon tubing while simultaneously squeezing the trigger of the repair tool. This action will clamp the connector onto the line.
3. Continue squeezing the trigger until the connector is fully seated and the barbs are securely engaged with the tubing.

4.3 Splicing into an Existing Line (Quick Union)

1. Ensure the existing fuel line is clean and free of debris.
2. Push the appropriate quick union onto the existing line until it is fully seated and secure.

4.4 Using a Brass Union for Permanent Fix

For a permanent repair, a brass union can be used. The process involves similar steps of heating the tubing and using the repair tool to secure the brass union onto the nylon lines.

5. Maintenance

Once installed, the Dorman 800-057 Quick Connector requires no special maintenance. Regularly inspect all fuel line connections for any signs of leaks, wear, or damage. Address any issues promptly to ensure continued safe operation of the vehicle's fuel system. Refer to your vehicle's owner's manual for recommended fuel system inspection intervals.

6. Troubleshooting

If you encounter issues after installing the Dorman 800-057 Quick Connector, consider the following:

• Fuel Leakage: Ensure the connector was fully seated and the barbs properly engaged with the nylon tubing. Re-check the connection for any debris or improper alignment.
• Difficulty Inserting Connector: If the connector is difficult to insert onto the tubing, apply a light film of motor oil to the connector barbs to aid in lubrication.
• Improper Fit: Double-check that the correct size (5/16 inch) connector and tubing were used for your application.

For persistent issues or complex repairs, it is recommended to consult an ASE Certified Automotive Professional.

7. Specifications

8. Warranty and Support

For technical assistance or questions regarding the Dorman 800-057 Quick Connector or other Dorman products, please utilize the following resources:

• Live Technical Support: 866-933-2911
• Website: www.DormanProducts.com

Please refer to Dorman Products' official website or product packaging for specific warranty information.