SAE J1624-2015 PDF

Full title and description

SAE J1624-2015 — Fuel Crossover Line. SAE International recommended practice that provides guidance and minimum recommended requirements for the design, installation and testing of fuel crossover lines used on commercial motor vehicles to reduce the likelihood of fuel leakage during normal operation and crash events.

Abstract

This recommended practice covers the functional intent, basic design considerations, materials and assembly features for fuel crossover lines (the piping or hose assemblies that connect fuel tanks or modules across a vehicle). It summarizes expected performance characteristics, routing and attachment principles, and basic test/inspection considerations used to verify integrity under pressure, vibration and crash-related conditions. The document is intended to help OEMs, suppliers and test laboratories reduce fuel leakage risk and improve crashworthiness of vehicle fuel delivery systems for commercial vehicles.

General information

• Status: Stabilized (active recommended practice).
• Publication date: October 15, 2015 (SAE product code J1624_201510).
• Publisher: SAE International (Society of Automotive Engineers).
• ICS / categories: Road vehicles / Fuel systems; vehicle crashworthiness and safety (road-vehicle engineering standards).
• Edition / version: J1624_201510 (2015). Historical: issued 2000; reaffirmed 2006; stabilized 2015.
• Number of pages: 8 pages.

Scope

This recommended practice applies to fuel crossover lines used on commercial, self-propelled motor vehicles that transport property or passengers. It provides recommended practices for acceptable design, materials, routing, attachment, and basic test checks intended to limit fuel loss from crossover lines during normal service and in crash or impact conditions. The document is advisory in nature and does not replace OEM-specific requirements; vehicle manufacturers may impose additional or more stringent requirements.

Key topics and requirements

• Purpose and definitions: terminology for crossover lines, assemblies and interfaces.
• Design recommendations: preferred routing, separation from heat and abrasion sources, support spacing and attachment methods.
• Materials and components: recommendations for hose, tubing, fittings and protective coverings compatible with common fuels and operating temperatures.
• Connector and fitting integrity: guidance on quick connectors, end-form compatibility and secure coupling methods.
• Performance checks and test considerations: pressure/leak checks, vibration and durability considerations, and inspection points to detect damage or wear.
• Crashworthiness considerations: routing and protection to minimize impact exposure and reduce the chance of post-crash leakage.
• Service and maintenance notes: inspection intervals, repair recommendations and replacement criteria.

Typical use and users

SAE J1624-2015 is used by vehicle OEM design engineers, fuel-system and crashworthiness engineers, Tier-1 suppliers of hoses and fittings, component designers, validation and test laboratories, and maintenance/service organizations. It is referenced during fuel system layout, supplier specifications, assembly procedures and durability/impact testing planning for commercial trucks and buses.

Related standards

Commonly used alongside other fuel-system standards such as SAE J30 (Fuel and Oil Hoses), SAE J2044 (Quick Connector Specification for Liquid Fuel and Vapor/Emissions Systems) and applicable regulatory requirements addressing fuel system integrity (for example FMVSS 301 in the United States). OEM-specific fuel-system specifications and connector/hose manufacturer standards are also frequently referenced together with J1624.

Keywords

fuel crossover line, fuel system, fuel hose, quick connector, fuel leak prevention, crashworthiness, SAE J1624, routing, fittings, pressure test, commercial vehicles

FAQ

Q: What is this standard?

A: SAE J1624-2015 is an SAE International recommended practice titled "Fuel Crossover Line" that gives recommended design, routing and basic verification guidance for fuel crossover lines used on commercial vehicles.

Q: What does it cover?

A: It covers recommended practices for crossover-line materials, routing, attachment, connector integrity and basic test/inspection considerations intended to reduce fuel leakage risk in normal use and crash scenarios. It is advisory and intended to be used with OEM-specific requirements.

Q: Who typically uses it?

A: Vehicle OEMs, Tier‑1 suppliers (hose and fitting manufacturers), design and safety engineers, test laboratories and maintenance/service organizations involved in fuel system design, validation and repair.

Q: Is it current or superseded?

A: The document was stabilized in October 2015 (product code J1624_201510). It supersedes earlier editions (issued 2000, reaffirmed 2006). Users should confirm with SAE International or their OEM whether a more recent revision or an OEM-specific specification applies.

Q: Is it part of a series?

A: It is part of SAE's family of fuel- and fuel-system related recommended practices and standards; it is typically used in conjunction with SAE standards that cover hoses, connectors and fuel-system components (for example SAE J30 and SAE J2044) and with applicable regulatory standards for fuel-system integrity.

Q: What are the key keywords?

A: Fuel crossover line; fuel system integrity; fuel hose; quick connector; crashworthiness; leak prevention; routing; fittings; SAE J1624.