Fuel lines in Tunnel?

[JRMock]

'87 911:

The current fuel line has a crack in the rubber section of the line between the fuel pump and the entrance to the tunnel.

What is the best way to replace, and/or repair these fuel lines?

It appears that the 'banjo' connections from the fuel pump goes from hardpipe to rubber, and back to hardpipe, which goes into the tunnel.

Do you have to drop the rack and pinion, and cross member to pull the hardpipe out the front? Or, does it pull out the rear?

Thanks,
JM

[DonMo]

I pulled mine out the front with a pull string tightly attached. This is a major pain job but doable. I pulled it out the front and back in the same way. I had to cut the rubber hose in the front to get it off. I replaced my fuel lines with rubber. I didn't want to pay the porsche tax of $80 a fuel line. If you do the supply, you really ought to do the return. I also found it beneficial to remove the seat from the car so I can help the line when I was snaking it back through. The other helpful clue was taking a jack and disconnecting the bolts to the tranny mount to get a little room to pull the lines back through. If you pay for OEM it will cost you $175 or so counting shipping, my local hydraulic hose guy made mine a $15 job, not including cuss words and sweat.

[fly944]

Be careful. You are dealing with a high pressure fuel system. Rubber is not the fuel line of choice. I believe most tracks wont let you on with more than 12 " of rubber in your system.

[David]

I'd use OEM, but I'm extra cautious when it comes to fuel. It's a pain but it can be done.

[JRMock]

DonMo ... did you leave the rack and pinion, and cross member in place?

Thanks,
JM

[ghnat]

I pulled mine out through the rear if I remember correctly - they seem to be more plastic than rubber. I did have the front and rear suspension out when I pulled mine - made it much easier. I have heard some folks using aeroquip in place of the lines going though the tunnel. I may do the same - not sure yet...

[David]

I just loosened the rack and pinion. It looks like you can't get the hoses through but you can.

[DonMo]

Rack and pinion stayed in place. I used high pressue line suitable for fuel. These hydraulic guys know what works with what. The guy who runs the shop is has a P-car too.

[rob justice]

This must be one of the worst jobs I carried out on an 85 Carrera. The supply and return pipes are made up from two parts the connecting unions being where the pipes leave the tunnel just forward of the gearbox. Splitting these pipes is a nightmare because the unions are buried below heater cables, clutch cable and gearbox linkages.
I found that by removing the gear stick allowed access into the tunnel - the fuel pipes partially run inside tubes within the tunnel from approx gearstick area to shift linkage cover.
The front pipes must be fitted from front to back. Tape up the unions to stop any dirt getting inside the pipes whilst fitting.
Be prepaired to loose most of the skin on you knuckles.
Sorry if I sound negative but its not a good job.

[88911coupe]

Rob, or anyone else for that matter, I'm trying to understand this situation since I have a small leak in the hose running from the banjo fitting on the fuel pump back to the hard line in the tunnel. Is this rubber hose a separate part or is it all part of the long hose running back into the tunnel? Is this just a 4-5 foot piece of plastic or metal tuning? I see connections or grommets that Pelican sells so can these be disconnected and or replaced?
TIA

[David]

It's all one peice.

[TWork]

If there's just a crack in the rubber line, you can replace that line without pulling the hardline out of the tunnel.

[ghnat]

If it will help, I'll post pics of my fuel lines tonight, I have them hanging in the garage somewhere.

[PcarPhil]

How hard would this job be if the drivetrain and steering rack are out of the car?

[88911coupe]

Twork, that's what I was planning to do but I'm a little confused about how to go about it. I'm not sure what to disconnect since the rubber line from the banjo fitting to the hard line crimped on right by the front bulkhead.

[ghnat]

The job is difficult, but with steering rack and drive train out that will make the job less difficult. One pain thing is getting the rubber gromets off. I had to cut and tear at them for a while before I removed enough material so they would come off. You can pull the fuel lines through the back side of the car.

[ghnat]

Actually, now that I think about it, I think I slid them out from the front of the car. that would make sense with the banjo fittings up front.

[David]

I've changed them with the engine in and out. It's doable both ways. I pushed the grommets out with a screwdriver and put in new ones after the fuel line was installed.

[88911coupe]

I would like to try and get at this from the front but can the large crossmember be lowered a bit. I don't know the part # since it's not listed in the Porsche parts catalog. It is connected by two large bolts but I'm not sure what sort of tension/stress is on it. I don't want to just loosen it and open a can of worms. Also, an I correct that the line back through the tunnel is not metal but plastic?
Thanks

[David]

I'd just remove the bolts on the steering rack. This will give you enough clearance to get the banjo fittings through.

The line through the tunnel is plastic.