Fuel Line Question

[chrisjcoe]

Hi all

After reading this excellent post, and with my MOT due in mid-June, I'd better start to think about last year's MOT advisory of corroded fuel lines. I don't want to repeat the above post and start a fuel line debate, I just have a couple of simple questions.

I am not prepared to spend the vast labour costs to have the axle dropped and an as-original, hard line installed, especially when so many people have had flexible/braided lines fitted without problem. I am also hoping to do all the work myself, and have a mechanic friend who would help out for a little monetary incentive if the going got too tough. So my first question is, is there a complete, off-the-shelf solution to replace the fuel lines from pump to regulator, or do you have to effectively make it yourself?

If it's a DIY job, can anyone point me in the direction of some suitable parts to buy? I don't want to go cheap, and I don't want to go top end. I'm after a sensible, reasonably priced solution. If metal, braided flexible pipes don't cost the earth, then that would be great, whether they just cover the joins to the pump and regulator, or run the entire length unbroken. If their cost is prohibitive, then I'd be happy with rubber fuel pipe, if it's man enough for the job.

I would also like to suggest that, if anyone has documented this job before, that it would be worthwhile having an FAQ for it, as I'm sure this is a job that a lot of people could tackle themselves.

Thanks

Chris

 

[Paul 290T]

Chris,

Modern cars have nylon fuel tanks. Thus when my indy suggested nylon re-piping from fuel filter to the rubber hoses that end just outside of the engine bay i agreed. He used brass fittings throughout. No need to drop the rear axle, clips into existing pipe clamp positions, won't rust, flexes with the body and only cost £180 fitted. That was over ten years ago, I've had no trouble since.

If you do some internet research i bet you can get all of the stuff you need for less than £30. The difficult bit will be finding out the fitting sizes.

 

[George Elliott]

Chris, there is a common sense approach to this subject like you read above, and there is another where the early 1980's design is rigidly adhered to and will incur costs IRO £1000

I opted for the common sense route, and a local motor factor source for British Standard Approved Fuel Line rated to double the pressure in our application (3 bar)

Note, the Factory approach still offers flexi hoses in the area above the exhaust manifold...[]

Good luck
George
944t

 

[david924s]

I had mine replaced front to back about 3 years ago with flexible lines normally used in a modern car Vauxhall I think, local mechanics did it in a day for around £180 but this included replacing the two short crossover brake lines on the rear as well. Been fine since, doesn't look standard but I don't spend much time looking underneath.

 

[chrisg]

Chris

I took the old fashion 'full' route and dropped the rear axle. I then took the complete brake lines from fliter to fuel rail to hydraulic hose specialist.

He used the hard lines as a template and provided SS braided hose with pressure coupling for over the rear axle and into engine bay over the exhaust. ISTR the cost for the parts was about £80.

I did it as a winter project, replaced all the rear brake pipes as well and the axle bushes - you don't have to do it this way.

80% of my fuel lines are still the original factory hard pipes = steel but with a corrosion inhibitor. Generally its only the section(s) that go over the rear axle that are the issue and need replacing.

I used Spectrum Hose in High Wycombe and Paul Rutter - very helpful, very switched on and very reasonable costs.

 

[Veerzigzag]

Thus when my indy suggested nylon re-piping from fuel filter to the rubber hoses that end just outside of the engine bay i agreed. He used brass fittings throughout.

This makes such good sense. A solution to keep in the back of your mind for that MoT or routine servicing dreaded phone call - many thanks for posting the idea.

 

[jmelhuish]

Has anyone made these up for and S2 themselves using Pirteck or someone similar? It would be very useful to know what dimension the connectors are and what diameter and length pipes are required for the job. I've read the various forums and the links and I don't have a clue what connectors and flexible (Braided?)pipe I should buy....My 944 is a daily driver and I would like to be in a position to buy everything I need then do the who job over one weekend.

TO learn more about my car I would like to try and do this work myself and any help is welcome.

 

[chrisg]

Jason

at the risk of stating the obvious.....

Are far as I'm aware the fuel pipes on an S2/Turbo/ late Lux are all the same. There is (10mm I think) a larger diameter fuel pipe that feeds the injection rail and a small bore return pipe.

If you use a pair of calipers or even an open ended spanner you can get a good feel for the OD of the pipe.

With regard to length, I would suggest a simple piece of string from one end to the other for the overall length. You can then gauge the amount of flexi pipe for end end using the same technique. Given that you're in Herts, my man Paul Rutter at Spectrum hose in Hemel is pretty close and knows the pipes having provided theme to me !

If you get really stuck I can measure up my flexi hoses at either end of the car - the fitments for the engine bay end and lengths will be slightly different as the manifold/ fuel rail arrangement is different on an S2.

Yours

Chris

 

[jmelhuish]

ORIGINAL: chrisg

Jason

at the risk of stating the obvious.....

Are far as I'm aware the fuel pipes on an S2/Turbo/ late Lux are all the same. There is (10mm I think) a larger diameter fuel pipe that feeds the injection rail and a small bore return pipe.

If you use a pair of calipers or even an open ended spanner you can get a good feel for the OD of the pipe.

With regard to length, I would suggest a simple piece of string from one end to the other for the overall length. You can then gauge the amount of flexi pipe for end end using the same technique. Given that you're in Herts, my man Paul Rutter at Spectrum hose in Hemel is pretty close and knows the pipes having provided theme to me !

If you get really stuck I can measure up my flexi hoses at either end of the car - the fitments for the engine bay end and lengths will be slightly different as the manifold/ fuel rail arrangement is different on an S2.

Yours

Chris

Hi Chris,
Thanks for the info. I was trying to work out the length and my mind had'nt computed using a pice of string Doh. Im only 10 miles from Hemel and will give Paul a ring and discuss.
Thanks and kind regards
Jason

 

[chrisg]

Jason

Paul Rutter can be contacted on:

Spectrum Hose 01494 524332

or his Mobile: 07770 753873

Explain about the fuel lines and mention my name and he'll remember about the compression fittings at either end,

Yours

Chris