2004 Pathfinder 2200TE: Changing/Replacing the fuel supply line, from tank to Raycor.

[Val2004]

I have a 2004 Pathfinder 2200TE.

I want to change the main fuel supply line from the tank to the fuel-water separator.  The tank has been pumped empty since a year ago.  I want to replace the aging fuel line before refilling the tank.  There are 2 potential problems:

1.  It’s next to impossible to access the spot where the line connects to the fuel pickup, using the existing round hatch inside the console.  I will have to cut the deck and install a larger 12”x16” rectangular hatch. This will also allow for changing the pickup unit.  Does anybody have an experience with installing such a hatch in the 22TE console?

2. But before I install the hatch, I want to make sure that the original supply line can be removed.  Has anybody done that?  If it is attached to the hull under the deck, can I just leave it in place and install the new line in parallel to the old one?  Can 5/8” OD hose be fished under the deck and into the transom compartment, to reach the fuel-water separator?

[smilemaker]

56 minutes ago, Val2004 said:

I have a 2004 Pathfinder 2200TE.

I want to change the main fuel supply line from the tank to the fuel-water separator.  The tank has been pumped empty since a year ago.  I want to replace the aging fuel line before refilling the tank.  There are 2 potential problems:

1.  It’s next to impossible to access the spot where the line connects to the fuel pickup, using the existing round hatch inside the console.  I will have to cut the deck and install a larger 12”x16” rectangular hatch. This will also allow for changing the pickup unit.  Does anybody have an experience with installing such a hatch in the 22TE console?

2. But before I install the hatch, I want to make sure that the original supply line can be removed.  Has anybody done that?  If it is attached to the hull under the deck, can I just leave it in place and install the new line in parallel to the old one?  Can 5/8” OD hose be fished under the deck and into the transom compartment, to reach the fuel-water separator?

@

[smilemaker]

I replaced the supply in my 04 22TE

I could not  remove the original hose. It is easier to go to the starboard side and snake the hose down the side. A little patience and an electrical snake will make it a doable job.

[Val2004]

Thank you, Smilemaker.  What about the access hatch?  I can see the pickup connection about 5 inches forward-right from the hatch, but cannot reach it to disconnect/connect the hose.

[smilemaker]

You will need to make a larger hatch.

Mine is a conglomeration of small pie holes. Wish it was one neater one.

[Val2004]

OK.  Purchased this hatch from Amazon:   CO-Z 17-1/4"x12-3/8'' Marine Access Hatch.

Made a plywood template for the cutout.  Here it is in the console:

That is how the hatch will look when closed:

Ready to cut the hole.  Will use the Ryobi version of RotoZip:  ONE+ 18V SPEED SAW Rotary Cutter  with a 1/8” bit. Will practice first on a scrap piece of fiberglass decking.

Did I forget anything?

[Wanaflatsfish]

Looks like it should work and give you enough space....just be careful with the battery wires....

dc

 

[Val2004]

👍

[fishmanjj]

That’s a nice size hatch and will provide good access below. 👍

[Val2004]

Finished the opening this morning.  Thank god it was cool. Had respirator and goggles on plus ear muffs.  Would suffocate if it were hot.  Now I can see and touch the hose connection.  Had to cut the old hose from the barb.  The hose fused to the metal in 17 years.

[Val2004]

I used this tile cutting carbide bit.  Bought it from Amazon Roto Zip TC4 1/8-Inch Tile-Cutting Carbide Zip Bits, 4-Pack,

Put some cutting oil on the line of cut so the bit would not overheat.

 

[Val2004]

On 8/23/2021 at 10:02 PM, smilemaker said:

I replaced the supply in my 04 22TE

I could not  remove the original hose. It is easier to go to the starboard side and snake the hose down the side. A little patience and an electrical snake will make it a doable job.

You were right.  The old hose would not budge.  I snaked the fish tape from the console back.  It came out about the same place as the old hose emerges from the bilge. 10 foot hose was barely long enough.  Connected the the tail end to the fuel-water separator.  Tomorrow will finish the tank connection.  

[smilemaker]

From the console  I was able to go almost 90 degrees to the side and then back to the  transom along the side.

You just have to look for an opening from under the  console. 

Forget about the rigging tube.

It is useless and for the most part just holds water around everything that is in it.

[Val2004]

Thanks Smile. See my edited post above.  

[Val2004]

Finally I am done.  Here is the new hatch both open and closed.  In the far right corner the new hose is connected to the tank outlet.  All the tank connections, including the sending unit, are easily accessible now.  I hope Maverick will make a big hatch standard equipment on future models.  On the other hand, it would deprive the future owners of an interesting DIY project. 😃

[Val2004]

Had to use the bit below to grind the cutout a bit (forgive me the pun), to match the hatch exactly.  (It was also handy to enlarge the holes in the bathroom counter, to match the new faucet size. )

 DT-DIATOOL Diamond Finger/Milling bits for Tile Porcelain Hard Ceramic Diameter 25mm

 

[Miss Jazzy]

12 hours ago, Val2004 said:

I hope Maverick will make a big hatch standard equipment on future models.  
 

Ive owned 3 Pathfinders, two ‘02 v’s and a ’06 tournament and none had that pie plate hatch. They all had a large square fiberglass lid about the size of your hatch from the factory.  Crazy yours is/was like that.

[smilemaker]

Tip for the future. 

First cuts should be with a hole saw having the proper radius. Just place hole saw on the hatch  to check.

Then cut the straight lines to connect.