fuel leak-how should I fix?

[rfuerst911sc]

For the past week I have smelled gas,I looked under the car,in the trunk and in the engine compartment and found nothing.Yesterday I raised the car up in the air and removed the plate that covers the steering rack/fuel pump and voila!! I found the leak.It appears that the hose coming out of the fuel pump(the end with electrical connections) leaks,but it's not leaking at the banjo fitting rather it is leaking at the crimp of the banjo fitting,how do I fix this? I followed the rubber hose and it goes over the top of the steering rack and then exits into I believe the "tunnel" that goes to the back of the car so where does the other end of the rubber hose connect,in the tunnel?I cleaned the leak several times with a rag and watched and it is definately coming from the crimp,any suggestions welcome.I assume the banjo fitting has copper sealing washers on either side?The car is a 83SC.................thanks.

[HarryD]

Originally posted by rfuerst911sc
For the past week I have smelled gas,I looked under the car,in the trunk and in the engine compartment and found nothing.Yesterday I raised the car up in the air and removed the plate that covers the steering rack/fuel pump and voila!! I found the leak.It appears that the hose coming out of the fuel pump(the end with electrical connections) leaks,but it's not leaking at the banjo fitting rather it is leaking at the crimp of the banjo fitting,how do I fix this? I followed the rubber hose and it goes over the top of the steering rack and then exits into I believe the "tunnel" that goes to the back of the car so where does the other end of the rubber hose connect,in the tunnel?I cleaned the leak several times with a rag and watched and it is definately coming from the crimp,any suggestions welcome.I assume the banjo fitting has copper sealing washers on either side?The car is a 83SC.................thanks.

I think you are talking about line #33 on the drawing below.



Once you get it out, you can take it to a Hydraulic Hose shop and have them crimp on a new rubber hose to your fittings. Be sure you get Fuel Injection Pressure Rated Hose. I think it would cost less than $20 to get repaired. Or you can get an new one from Pelican for $78.50 plus shipping.

As far as how to remove, I can't help you there but I belive there have been several threads on fuel lne replacement in the tunnel that you can search for.

Hope this helps.

[rfuerst911sc]

You are correct Harry that is the line that's leaking,I will do a search to see about how to replace it.Thanks

[cowtown]

I know you said that the leak is at the crimp and not the banjo, but this type of leak can be extremely deceptive to look at...it's fooled me more than once. It is possible that the banjo is too loose, too tight, or that the crush washer under the banjo bolt is not sealing. The gas can flow toward the crimp and soak that area, making it look like the crimp has failed.

Given the cost and time involved in repairing or replacing the line, why not try a new crush washer at the banjo fitting first?

Good luck!

[rfuerst911sc]

Good suggestion Colin it's worth a shot.I must say it sure looked like it was leaking out of the crimp and running down with gravity but I'll take your word that it can be the other way.

[dmarv]

I had the same problem with my '76 911 this weekend. My suggestion would be to replace both fuel lines. I fixed one, then the other started to leak a week later. I own an auto parts store, so I crimped the new fuel hose on myself. If you take both lines out at the same time, remember the return line is on the drivers side and supply line is on the passengers side. You will need to remove the transmission mount bracket to get better access where the lines come out of the tunnel. It takes a 17mm and 11mm wrench to remove the rear section of the hoses. When I removed the lines from the tunnel I attached a heavy string on the hose. When I reinstall the hoses I will use the string to pull the line through the tunnel. Hope this helps.

[David]

Replacing pressurized fuel line from pump on 78 SC?

[rfuerst911sc]

Update-it turned out it was the crimp that was leaking,I took the car to my mechanic and he "patched" in a new section of rubber hose with hose clamps,it's holding for now and the car is back on the road.In the spring I'll probably have new lines(supply and return) done so I know it's all up to snuff.Thanks for all that replied.

[HarryD]

rfuerst911sc,

I would be wary of a hose clamp repair since on high pressure lines, they can fail rapidly and catastrophically.

[john walker's workshop]

do you have a fire extinguisher in the car?