Stupid leaky t fuel line

[Jp-oh]

So my fuel line that splits to the rails started leaking today. I've got it all disassembled and it is free (all the little ****ty bolts at the back too) but I cannot figure out how to pull it from the car. Is there a trick? I figured id be able to finagle it back to front under the manifold. It seems to be hanging up on the drivers side where the rubber line from the fuel pump couples with the start of the metal line. Like the little bracket attached to the metal line is getting stuck.

[KTL]

My recollection is you need to get the long throttle return springs under the manifold removed. Also take a look at the bellcrank assembly under the manifold. The curved rod from the bellcrank to the throttle body may get in the way of the line coming out.

[john walker's workshop]

the temp sensor on the breather will break if you don't remove it first. the line needs to be bent a bit to come out. PITA with the engine in the car. i take the engine out now.

[Jp-oh]

I have a feeling I need to take the fuel pressure regulator off. I was hoping to avoid that. But I literally can't get the end by the pump past that spot. The bracket attached to the beginning of the metal hard line keeps getting hung up in the area of the fpr.

[VMAX1]

About 6 years ago, mine started leaking and would have been the second time I replaced it. I cut it out and to the hose to a shop that built race cars. They made me a custom, braided, setup with the old fittings. No more pita gettin it off. Also, was cheaper than eom replacement. Just an idea

[Jp-oh]

I've already talked to a place about fabing a replacement so I don't know if I care too much about the old one. So the rubber bits are fair game for chopping but I'd be reluctant to out and out destroy the hard lines just yet.

[KTL]

I'm not speculating on getting the fuel line out with the engine in place, intake manifold NOT removed. It can be done.

I know when I did a couple of them, the fuel pressure regulator and the damper did not need to come off. Keep looking around for the hangup. And I recall we did not cut the line at all when taking it out. Took some shoe-horning to get it out but we got it out both times we did the job on two different cars.

[Marc Bixen]

We leave the motor in, but pull the intake manifold. It's not that bad. With experience it's a 3-4 hour job. The other reason we pull it is that 3.2 intake manifold, especially early ones, are notorious for loosening up. So it gives us the opportunity to replace the 12 intake gaskets and the 6 insulator plates, which sometimes crack. Early 3.2's used a standard m8 flat washer and this was part of the issue with them loosening up. On the later cars Porsche updated to a thicker washer that prevented this. ( order 12x 99902515202). Also don't forget to replace the fuel return crossover hose, 93011041103) as we've seen many of these leak soon after and they're only $92.03.

[Jp-oh]

This is the setup I'll try and have the shop emulate:

carrera fuel line, (BAT and AN fittings)

I am going to at least take off the line between the regulator and damper as I should replace it while all the other crap is disassembled anyway.

This seem reasonable?

[BoxsterGT]

Here's my "soft" replacement for the main "Tee" hose assembly in either E-85 rated plain rubber hose..............



or E-85 rated Braided SS............



For details, please email me. I do not accept PMs.

Len at Autosportengineering dot com

[Rich Gas]

I installed Lens stainless replacement. Very well made and went in easy. I cut the T line by the rear of the manifold. Removed only the filter, afm, blower motor. Use a dremel. Watch for sparks.
Rich G

[Jp-oh]

I've decided to destroy the old one with extreme prejudice. PS Boxter, you've got mail..

Cheers,

[Rich Gas]

Jp make sure you replace all three compartment lines. Easier with all the stuff off anyway. I used a crows foot 17mm, 19mm. A small mirror on a stick is your friend.

[Jp-oh]

Small hack saw and big snips and it's out. F-u gas line. F-u.

[Smoove1010]

Good move contacting Len. I fabbed my own fuel lines using braided hose and AN fittings, and was sorry I did so:
Fuel Smell Mystery: 3.2 Carrera

...so I had to RnR my fuel lines just like you're doing. I removed the intake manifold to do so, and I think it's the best way to do this job. fiddling with the throttle return springs was the tedious part, the rest is pretty straightforward nuts-and-bolts.

Good luck!
GK

[GeorgeK]

Len, tried to email you about a week ago, no dice?

[BoxsterGT]

Should be OK now.

I was away and my Verizon e-mail account got too full. In my old Windows XP I kept my own email account. With Windows 7 I have to let Verizon take care of it and I am very unhappy with their service.

Anyone know how I can get back to my own account on my own desktop?

Len

[nene]

Len, I can help with your computer request (I am in the IT world). I would like to talk to you regarding the fuel lines for an 86 carrera. You can pm me with your contact info if you'd like.

Serge

[BoxsterGT]

Serge-

I do not do PMs, my box is always full and I cannot send photos via PM. Please add your email to your user info and I will email you.

Thanks,

Len

[GeorgeK]

Len, email sent.