911sc fuel line leak

[stevebmd]

my 1978 911sc targa is leaking fuel from the high pressure fuel lines leading to the transmission tunnel. At first I thought it may be coming from the Banjo bolt and copper washers, but after replacing the washers and tightening it still as leaking from the fueling after the connection. I have both Haynes and Bentley manuals but neither touch on this problem or repair, any experience would be helpful

[targa80]

The rubber/ metal fuel line from the fuel pump to the tunnel operates under high pressure and can be replaced. You can replace the whole line by removing clamps located in the tunnel and pulling it through (not an easy job).The rubber gas line of the banjo fitting is crimped under high pressure. In 2012 my rubber gas line started leaking and knowing how difficult it is to replace I decided to just replace the rubber portion of the gas line using Dorman fuel injection line clamps. I cut away the metal crimps and the metal line and banjo fitting both had ridges to support the rubber hose and Dorman clamp. I found it to be an easier fix that saved me time and money. Naturally, a full replacement of the line is the preferred method due to the fuel pump high pressure. In my own case I have a level of confidence in my repair that I am not concerned with the repair option I chose.

[BoxsterGT]

The originals are close to 40 years old and a catastrophe waiting to happen. They are way overdue for replacement.

This is what Pat is speaking about.....



For a temporary repair this will work....


Along with a proper Norma Hose Clamp.....


For a more permanent, long-term solution you should replace the entire Tunnel System, Front & Rear.....


These replacements for the SC are E-85 rated and far superior to the originals.

Please email me for info. NO PM's as my BOX is FULL.

Len dot Cummings at verizon dot net

[targa80]

Attached is a page from pet showing the front fuel lines. Item 33 which is the high pressure side of the fuel line from the pump to the fuel filter. Item 38 is the return line back to the tank. I only replaced the rubber portion from the banjo fitting to the hard line entering the tunnel.




Front fuel lines near fuel pump just before removing them from the car back in 2002.



This is a picture of the two fuel line exiting the rear tunnel. the Hard lines are colored green.


Now you know why I decided to just change the rubber in the front. the photos were taken in 2002 when the car had the engine out and the front suspension removed just prior to removing all of the electrical/fuel/brake lines in the tunnel. I did not find the failure until after everything was back in the car and running. I realized that I did not want to go through the hassle of trying to remove the tunnel fuel line at that point especially since I had removed and reinstalled everything once before.

[uwanna]

Originally Posted by targa80

The rubber/ metal fuel line from the fuel pump to the tunnel operates under high pressure and can be replaced. You can replace the whole line by removing clamps located in the tunnel and pulling it through (not an easy job).The rubber gas line of the banjo fitting is crimped under high pressure. In 2012 my rubber gas line started leaking and knowing how difficult it is to replace I decided to just replace the rubber portion of the gas line using Dorman fuel injection line clamps. I cut away the metal crimps and the metal line and banjo fitting both had ridges to support the rubber hose and Dorman clamp. I found it to be an easier fix that saved me time and money. Naturally, a full replacement of the line is the preferred method due to the fuel pump high pressure. In my own case I have a level of confidence in my repair that I am not concerned with the repair option I chose.

Did the same fix 5 or six years ago using ethanol rated fuel injection hose. Great fix, probably as durable as the original hose or perhaps more so because newer hose is not affected by ethanol. No problems
at all, but if you feel uncomfortable with sourcing your own parts, buy the repair kit from BoxterGT.

[rushi]

Hi All,

where could i buy the hose and banjo combo that's posted by BoxsterGT in the second image

Even the Banjo alone would do.

[OSC911]

Len (BoxsterGT) makes them up. Shoot him an email. He has helped a lot of guys out - including me with their fuel hose needs.

Len dot Cummings at verizon dot net

[GH85Carrera]

Those photos of the fuel lines above is are great, but that is with the engine out of the car. It is very possible to replace those lines in the tunnel with the engine in place, but it is much more tedious.

You will have to support the transmission, and remove the transmission mount, just to see the fuel lines at the rear.

Get the set from Len, as he provides a neat little coupler so you can hook the old lines to the new to pull the new ones into place much easier. And find a friend or helper when you are ready to pull them through the tunnel. It takes a lot of "push and pull" and wiggling to get them to go through.

Do a search on the forum for tunnel fuel lines and read the other threads.

Good Luck!

[scotricker]

I just finished replacing mine, on my 78SC, with Len's new hoses. I replaced them all.
Engine out seemed to be the easiest way. Engine is back in now, finishing up soon.

[1Bad86]

I'll be doing all of mine from front to back including engine compartment lines with engine in. I would rather spend a weekend cussing than years crying after my car burns to the ground from a leaky 34 year old fuel line. I remember a quote I read on the Turbo forum years ago when giving advise on buying a car that relates well "There are no cheap Porsche's , Either pay now or pay later but either way you'll pay". As many others will vouch reach out to Len.