Dorman 800-195 Fuel Check Valve 5/16 Instruction Manual

1. Product Overview

The Dorman 800-195 Fuel Check Valve is designed to prevent fuel from back-flowing within the fuel system, addressing issues caused by a failed or leaking original equipment check valve. Constructed from durable metal and fuel-resistant plastic, this valve is engineered for longevity and reliable performance. It includes all necessary hardware for a complete installation.

Key Features:

• Ideal Replacement: Direct fit for failed or leaking original equipment check valves.
• Durable Construction: Manufactured from high-quality metal and fuel-resistant plastic.
• Complete Solution: Supplied with all required installation hardware.
• Professional Endorsement: Trusted and utilized by automotive service professionals.

2. Safety Precautions

Always prioritize safety when working with automotive fuel systems. Fuel is highly flammable and can cause severe injury or death if not handled properly. Ensure adequate ventilation and have a fire extinguisher readily available.

• WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
• IMPORTANT: This fuel check valve is NOT FOR USE WITH CARBURETED VEHICLES. It is designed for fuel-injected systems.
• Disconnect the vehicle's battery before beginning any work on the fuel system.
• Relieve fuel system pressure before disconnecting any fuel lines. Consult your vehicle's service manual for specific procedures.
• Wear appropriate personal protective equipment, including safety glasses and fuel-resistant gloves.
• Ensure the work area is free of ignition sources, such as open flames, sparks, or hot surfaces.
• Dispose of any drained fuel or contaminated materials according to local regulations.

3. Package Contents

Verify that all components listed below are present in the package before beginning installation. The image below illustrates the typical contents.

Image: The Dorman 800-195 Fuel Check Valve (top center) shown with its accompanying installation hardware, including various brass fittings, a nut, a mounting clamp, washers, and a screw.

• 1x Dorman 800-195 Fuel Check Valve
• 2x Brass Fittings (various types for connection)
• 1x Hex Nut
• 1x Mounting Clamp
• 2x Washers
• 1x Self-tapping Screw

4. Technical Specifications

5. Installation Guide

This guide provides general steps for installing the Dorman 800-195 Fuel Check Valve. Specific vehicle configurations may vary. If you are unsure about any step, it is recommended to consult a qualified automotive technician.

1. Prepare the Vehicle: Ensure the vehicle is on a level surface and the engine is cool. Disconnect the negative terminal of the battery. Relieve fuel system pressure according to the vehicle manufacturer's service manual.
2. Locate Installation Point: Identify the section of the fuel line where the check valve needs to be installed. This is typically near the fuel pump or where back-flow is occurring.
3. Cut Fuel Line: Carefully cut a section out of the existing fuel line to accommodate the length of the new check valve and its fittings. Approximately 3.5 inches of fuel line removal may be required, depending on the specific fittings used. Use a sharp, appropriate cutting tool to ensure clean cuts.
4. Install Fittings: Attach the appropriate brass fittings to both ends of the Dorman 800-195 Fuel Check Valve. Ensure the arrow on the check valve body points in the direction of fuel flow (away from the fuel tank, towards the engine).
5. Secure Connections: Connect the prepared fuel lines to the fittings on the check valve. Ensure all connections are tight and properly sealed. It is highly recommended to use a suitable fuel-resistant thread sealant (e.g., Permatex or yellow PTFE tape) on all threaded connections to prevent leaks.
6. Mount the Valve: Use the provided mounting clamp and screw to secure the check valve to a stable surface, preventing vibration and strain on the fuel lines.
7. Reconnect and Test: Reconnect the vehicle's battery. Turn the ignition to the 'ON' position (without starting the engine) for a few seconds to allow the fuel pump to prime the system. Check for any leaks around the newly installed valve and connections. Start the engine and re-check for leaks.

6. Operation

The Dorman 800-195 Fuel Check Valve operates as a one-way valve. It allows fuel to flow in only one direction, as indicated by the arrow on its body. This prevents fuel from draining back into the tank when the engine is off, which can cause extended cranking or hard starting issues. When the fuel pump operates, pressure opens the valve, allowing fuel to pass through. When the pump stops, the valve closes, maintaining fuel pressure in the line.

7. Maintenance

The Dorman 800-195 Fuel Check Valve is designed for long-term, maintenance-free operation. However, periodic inspection of the fuel system, including the check valve and its connections, is recommended as part of routine vehicle maintenance.

• Visually inspect the valve and surrounding fuel lines for any signs of leaks, cracks, or damage during regular service intervals.
• Ensure mounting hardware remains secure.
• If any issues are detected, address them promptly to prevent further damage or safety hazards.

8. Troubleshooting

If you experience issues after installing the Dorman 800-195 Fuel Check Valve, consider the following common problems and solutions:

• Fuel Leaks:
  • Cause: Improperly tightened fittings, damaged seals, or insufficient thread sealant.
  • Solution: Re-check all connections for tightness. Disassemble, inspect seals/washers, and reapply appropriate fuel-resistant thread sealant if necessary. Ensure fittings are not cross-threaded.
• Continued Hard Starting/Extended Cranking:
  • Cause: Check valve installed backward, air in the fuel system, or another component failure (e.g., fuel pump, fuel pressure regulator).
  • Solution: Verify the check valve is installed with the arrow pointing in the correct direction of fuel flow. Bleed any air from the fuel system if applicable. If the problem persists, diagnose other fuel system components.
• No Fuel Flow:
  • Cause: Check valve installed backward, obstruction in the valve, or severe fuel line kink.
  • Solution: Confirm correct installation direction. Inspect the valve for any internal debris. Check fuel lines for kinks or blockages.
• Incompatibility with Carbureted Systems:
  • Cause: Attempting to use the valve on a carbureted vehicle.
  • Solution: This valve is designed for fuel-injected systems. Do not use it with carbureted vehicles as it may not function correctly or could cause fuel delivery issues.

9. Warranty and Support

For specific warranty information regarding your Dorman 800-195 Fuel Check Valve, please refer to the warranty documentation included with your purchase or visit the official Dorman website. Dorman Products stands by the quality of its automotive replacement parts.

For additional support, technical assistance, or to explore other Dorman products, please visit the Dorman brand store:

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