Replacing pressurized fuel line from pump on 78 SC?

[David]

I've just gotten my friend's 78 SC that's been living in my garage for 2 years running good... no, great. Now another problem has cropped up. The pressurized line from the fuel pump has a leak just above the crimped banjo fitting at the pump.

My question is: is it a single line that runs from the pump to the engine compartment and if so how much is involved with replacing it?

I've done some searching and found some pretty scary info, but I'm looking for an answer in plan english. Thanks.

[David]

I did some more searching and even found where this question was asked with no real answer.

So my new question is: can the stock hard line be run through the body with engine and/or steering rack still installed?

[Jim Sims]

I haven't done this particular task but my experiences with work in the tunnels of a '73.5T and '76S: new throttle linkage bushings, rebuilt shifter and shift coupling bushings, new speedometer cable, new clutch cable, pulled the horizontal portion of the shift rod for repair (has to come out the back with engine out) indicate you will likely need to drop the engine and pull the old lines rearward and install the new lines by pulling them forward. The steering rack can probably stay in place but if loosened it would make work up front more pleasant. It was possible to replace the rubber sections of the '73.5T fuel lines without tunnel work as they were attached to the metal tunnel lines with reusable clamps just outside of the tunnel. Not your exact task but some information. Maybe someone else has put in the OEM lines will respond. Jim

[David]

Come on, anyone done this?

I've done some more searching and I can't find anyone that's successfully replaced with a stock hose.

I'm getting the impression that I'll need to get access to the tunnel through the car by removing the seats and carpet, but I'm also getting the impression that I'll need to remove the engine. Anyone?

[David]

OK, I'm officially begging now. I know someone out there has replaced this line.

[David]

Well, I finally replaced the fuel line from the fuel pump on the 78 SC. Since nobody replied to my original post with suggestions on how to do this, I'll assume nobody's done it and someone else might need some advice so here it is. By the way, it did not require pulling the engine.

Removing the old fuel line:
1) Support the transmission
2) Remove the rear sway bar and front transmission cross member.
3) Disconnect the fuel line from the fuel pump to the accumulator line. Looking at the two fuel lines coming out of the rear bulk head on the driver's side of the shift rod, the one on the driver's side is the return line, the one on the passenger side is the pressure line. Disconnect this one. It takes a 17mm and 11mm, although I used vice grips on the 11mm flats since the wrench was slipping. Have a catch pan ready for the fuel.
4) Go inside the car and remove the panel under the pedals, the gas pedal, and the panel over the shift coupling.
5) Using a screwdriver, push out the rubber grommets from the inside.
6) Pull the hose out from the front, it should pull out pretty easy. It's the one on the passenger side.
7) Remove the fuel line fitting at the fuel pump. Have a catch can ready, mine only let out a little fuel and stopped.
8) Pull the line from over the steering rack. It's a little difficult getting it through the metal guide above the steering rack but a good hard pull should do it.

Parts needed:
C-356-066-07 (this is for a 930 but appearantly it's the only one available now, do not order C-356-066-06, it's not the right one)
Two, C-356-202-03 (Rubber Grommets)
One, K-134-018-02 (12mm Hollow bolt since your installing a 930 line not the 10mm original line)
Two, N-013-812-2 (12mm sealing rings)

Installing the new one:
1) Remove the 3 bolts holding down the emergency brake lever in the car.
2) Put a piece of tape over the end of the fuel line to keep out dirt.
3) Have a helper feed the fuel line in from the front bulk head.
3) Pull up the carpet in front of shifter console and help guide the fuel line through the tunnel on the top of driver's side as your helper feeds the line.
4) When the line reaches the emergency brake opening, reach into the tunnel and guide the line along the return line on driver's side. A flashlight and mirror help in keeping track of where it is.
5) Do the same when it reaches the shift coupling opening.
6) Tell your helper thanks, you can go back to watching TV (in my case that would be my wife)
7) Go under the car and feed the front of the line back through the metal guide above the steering rack. YES, IT'S POSSIBLE. Then attach the banjo fitting with the new bolt and washers. When tightening the bolt, be sure not get the hose in a bind.
8) Slide the new grommets over the line at the front and rear bulk heads and push them in from the outside. I used a little silicon spray and a screwdriver.
9) Attach the line at the rear and put everything back together.

In hind sight, I wish I had replaced the return line at same time.

[masraum]

David, wow great to hear that you finally got the SC running. Sounds like replacing that fuel line was a job.

I've got a different job now so I am not working weekends any more, so possibly I'll be able to attend a HouPelican get together or something. I still haven't seen or riden in your Turbo yet.

[David]

Steve, the SC's running good and will hopefully leave my garage soon.

Still sorry to hear your selling the car, any chance of keeping it now that you have a new job?

You should come by sometime and check out the 930 before the engine comes out for some major upgrades. I'm getting the EFI bug!

[ecm911]

David,

Thank you very much for your detailed post. I used it this weekend installing both fuel lines in the tunnel. The project car we are working need to have them installed, in fact the entire fuel system, except the tank was removed.

Your post help greatly, it was the only source that identified which side each line was on. This is important and damn near impossible when you have no guide.

I have on last question, If I may - regarding the two hard lines in the rear. How are they run- specifically there is a series of metal hoopes (my description) about 4 -5 ( if memory is correct) along the body from the tunnel to the right next to the fuel filter/ accumlator. This is the exact route of the hard lines. My question, do the hard line run inside these hoopes? If so, how do you get them in there? and 2, what prevents them from rubbing against the body or the hoopes?

Thanks again!!!!!

Earl

[David]

Earl,

Glad to help, unfortunately the SC is gone and the only line I replaced was the one through the tunnel. I plan on replacing all the lines on my 930, but that is several weeks away.

One question though, why are you replacing hard lines?

[ecm911]

David,

The PO removed the entire fuel system. So I am installing new ones, because there are none now.

Thanks again and good luck.

Earl