oooo that smell... Leak in fuel line. Help!

SuperD · 07-21-2004, 05:35 PM

Finally - I found the source of that noxious fuel smell ('85 Carrera). There is a pin hole in the fuel line about 2 inches above the fuel pump check valve fitting. Does this line go all the way through the tunnel? Or can I replace just that small section that goes from the pump into the tunnel? Whatta I gotta do?

Rot 911 · 07-21-2004, 06:17 PM

If it is the metal line, it goes all the way through the tunnel and is a ***** to replace. By the way, if it is the metal line, take a wax candle and rub it vigorously over the pinhole leak. Good chance the wax will plug the pinhole, at least for a short period of time. (Just one of those things you learn working on British cars)

SuperD · 07-22-2004, 05:12 AM

The fuel line has a metal fitting that goes on the fuel pump, but the leak is in the rubber hose, just up from that. It looks like the rubber hose dissappears into the tunnel..?.. I was hoping there was another fitting at the tunnel and I could replace just that small section. Any help is greatly appreciated!

mtelliott · 07-22-2004, 07:16 AM

I thought that only metal lines run through the tunnel. You have a supply that goes to the fuel filter (hard line) and a return line (rubber) from the fuel injection system that connects to a hard line that returns to the tank. Can you take a picture or point to a diagram?

SuperD · 07-23-2004, 06:07 AM

I got her all fixed up last night. Had to cut the crimps off of both ends of the line and use clamps. Thanks for the help!

88911coupe · 02-03-2007, 03:05 PM

Super D, I think I have the same leak as you did. Mine is part #911 -356-066-07 from the parts catalogs and I can see fuel slowly run down it when I turn the car on with the protective plate out of the way. The problem is I can't tell how to get this other end off since it seems to dissappear back into the tunnel. I can obviously remove the banjo fitting on the fuel pump side but where does the other end go...how far into the tunnel does this go and what has to be removed to get to it?
HELP...car's on jacks and I need to get to work Monday.
THANKS!

Walt Fricke · 02-03-2007, 08:56 PM

How about this: Cut the hose at the leak. Right through the hole. Insert a proper sized two ended barbed brass coupler fitting. 1/4"? Maybe 3/8"? You want a tight fit. You should be able to get those from a good hardware store (though you might want to check that out before cutting). Push the two hose ends together over the barbs. Get two small hose clamps, too, and finish the job with them, one on each side of the joint you have made.

Then you can figure out what it takes to do a better repair.

Walt Fricke

88911coupe · 02-04-2007, 06:23 AM

Walt, thanks for the suggestion but I'm having trouble telling exactly where the leak it. What's odd is that I decided to go ahead and change my fuel filter since I'd just ordered one from our host and when I ran the car to see if the filter was on good and tight I noticed the leak up front is now not leaking, which is really odd. I moved the rubber line around a bit trying to get a better look and I think I may have somehow closed the leak, obviously temporarily. Bottom line is I'd like to just change the rubber line going from the fuel pump the the hardlne in the tunnel but it does not appear possible. On the Parts and technical ref catalog it shows a "sleeve" part #911-356-202-03 which seems to imply that's how the rubber line from the pump is connected to the hard line.
Any instructions would be appreciated...

Walt Fricke · 02-04-2007, 01:52 PM

My notion on how to chase down a leak of this sort: air pressure + soapy water. Just like a tire.

I think I'd make up a fitting I could screw into the fuel line in the rear where the filter attaches. I have a bunch of those filter fittings, which I took off of old filters before throwing them away. Very useful. I'd drill and tap or weld an air hose fitting onto one of those. I recently did just that as a safe and convenient way of using the fuel pump to drain about 18 gallons of fuel from the recently filled (naturally) tank into containers.

In the front I'd pull the banjo fitting off, and using some steel washers and some copper/aluminum washers, and a bolt and nut, and maybe some sort of goop, block off the banjo.

Then let the pressure rip and start applying the water.

Don't know just how I'd do that for the return line, though. Maybe it will mate with fuel filter fittings also?

I think the most likely place for a leak is at the banjo fitting, but that is most likely to happen after a pump has been replaced or at least a wrench applied in that area.

It is quite possible to crack the hollow bolt fitting that screws into the pump and holds the banjo and its nut. Same sort of deal as the rear right side cam line case fitting. That can happen without recent wrenching as a result of overtightening in the dim past.

Walt Fricke

88911coupe · 02-04-2007, 02:02 PM

I can tell that the leak (which has mysteriously stopped, temporarily I'm sure) was where the rubber line goes up over the heavy suspension part that is bolted to the main body. I think it sounds like from reading Super D's comments about I have to just cut the sleeve off at the metal part and use clamps on the replacement hose. I can't imagine getting any sort of crimping device on another sleeve up there, there is no room.
THanks