Replacing Gas lines

[GaryR]

Is there an easy way to do this? I noticed the fittings on the car i'm building are quite corroded and I really don't want to trust 30+ year old lines anyway. The gas tank is out, as is the engine/transmission so now is the time. And where do you get replacements? Have to have them custom made? Cut the OE lines and pull new ones through attached to them?

Thanks for any help to make this go a little easier..

[trconway]

I'm interested in this too.

Tom in NJ

[vmax]

Some good info Gary

Fuel Return Line

How hard is it to change the fuel lines?

In tunnel fuel line replacements?

[vmax]

This thread has a great picture of what is inside of the tunnel:

Need help with fuel line install - '88

[GaryR]

A lot of good info, thanks Doug! I'm going to be using PMO's pressure regulator so i'll have to get what type of fittings i'll need from him for the engine end. I plan on staying with the OEM fuel pump and will need both gas tank connections and the banjo fitting on the pump... basically everything.... For all I know what is on there now has been bastardized, i'll take a pic tomorrow.

[GaryR]

Well, I just ordered the two lines that go through the tunnel and they will be coming from Germany (unless I get word they are NLA). The lines themselves really don't look bad but the fittings do. Either way they needed to come apart as they were completely plugged up in the rear where the secondary hoses connect. All I will need from PMO (or NAPA) is the hose from the tunnel feed line to the pressure regulator and the return line from the carbs to the tank. A couple pics to show where i'm at... they are soaking in Aero-Kroil, which worked as they came apart with no drama.


Front Fittings


Rear Fittings



Plugged return

[DonMo]

I took my hose and fittings out and went to a my local hydraulic hose shop and $10 later, they had cleaned up the fittings, added the right fuel hose (psi and diameter) and then all I had to do was fish the hose back through. No small task but doable with some soap for lube and a strong piece of stranded string.

[GaryR]

There wasn't any cleaning up of those fittings, trust me. They look better in pictures than in person. If I knew of a place that could build me new lines identical to these I would gladly do that but I don't want any part of this junk between my new gas tank and my 46mm Webers!

[David]

I bought OEM from Pelican, don't know if they're still available.

You can make them with braided for about the same price

Either way, I wouldn't drive a 30 yo 911/930 without new lines. Too big a fire risk.

[GaryR]

Lines came today.. gas line porn..

[Jim Sims]

Heads up: The gas lines are retained by sheet metal tabs in the tunnel; one needs to access the tunnel via the various openings (shifter, hand brake, shift coupling cover) and spread these tabs prior to pulling out the old lines; once the new lines are in place, the tabs should be folded back over the fuel lines to keep them in place and out of the way of the moving linkages in the tunnel. This would also be a good time to replace the three soft plastic throttle linkage support bushings in the tunnel. The plastic grommets retaining the fuel lines (find under the tar-like sealant) at the front and rear of the tunnel are often very difficult to remove and may be destroyed or severely mangled in the process; you may want to have four replacements on hand.

[GaryR]

Thanks Jim, i'll be sure to get the tabs moved. I plan on completely rebuilding the shifter and the throttle linkage while everything is apart.

I got 4 nice new grommets from Porsche with the new lines.

[GaryR]

A follow up -

The lines went in fine, took a total of about an hour with climbing in/out to help them along. Had to pull one back and redo the string to create more of a "rat tail" with the string and electrical tape as it was jamming up with the other line down in the final part of the run. As you may notice from the picture, Porsche, in their infinite wisdom changed the type of fitting on one of the lines. The originals were both the "concave" type, now one is convex. If I were using their lines from that point on I (hope) they would have the correct one to go to the next part of the CIS system but i'm not. There is an adapter to go from the concave fitting to AN -6 but the one for convex doesn't exist. Luckily Greg at J2 Precision is a Porsche guy ( J2 Precision Hose and Fittings ) and came up with a solution using a 928 fuel rail part! It will take two adapters but problem solved, and i'll get all the lines and AN fittings from them to get to my PMO regulator. Now if I want to go EFI down the road i'm ready!