new fuel lines

[85911]

On my '86 911, I smell gasoline fumes when I fill up all the way. So, I replaced the large diameter rubber hose between the filler neck and gas tank.

I also replaced the 3 lines in and out of the white plastic expansion tank. I couldn't find any metric fuel line locally, so I used the closest imperial sized hoses until I can order metric.

The upper, smaller diameter line coming out of the expansion tank is crimped because of the 180 deg. bend it must make.

In my experience, cloth braided hose, which I intend to order, is more flexible.

Is this crimp acceptable?

Also, the PET diagram shows a "restrictor", no. 19 in the diagram, part no. 911 201 263 02. When I took off the old line, I didn't see this part. Is it needed?




Thanks.

[DerkPerk]

That looks quite restrictive, however it is just the vent. Not sure what side effects you’ll see.


Sent from my iPhone using Tapatalk

[Trakrat]

I think the hose is too long on the left. That plastic part needs to be moved further back. It doesn't normally extend over the gas tank like that.

There should never be a crimp like that with a fuel line.

[85911]

Trakrat: I cut the new, larger diameter. hoses the exact same length as the original which placed the plastic tank in the original position. I cut the smaller diameter hose, which is crimped, slightly longer. It wouldn't matter if it were shorter- the crimp would still form. If this system is truly overflow, the crimp may be restrictive. But, if it's for vapor, it may not matter.


DerkPerk: I agree if it's a vent line, but the PET Katalog labels the tank as an expansion tank.

I suppose if I never filled my tank to full, it wouldn't be a problem.

[85911]

After I replaced the filler pipe rubber hose and the rubber lines in and out of the expansion tank, I went to the gas station to fill up and see if I solved the problem and test my connections.

I opened the hood to observe and all my connections were good, but I saw fuel seeping from a pinhole in the metal filler neck near the small hose connection going to the expansion tank.



When I looked closer, it appears JB Weld had been applied at this point.

I will try to remove as much as the epoxy as I can and take it to a good welder- I don't trust myself when welding on fuel handling equipment.

Can anyone give me an opinion on the importance of the restrictor shown in the PET Katalog, pg. 201-15, no. 19?

My PET Katalog is for a 1986. Is there a separate PET for an "85? I see a few subtle differences at times, so I'm wondering if my "85 had a restrictor. It's difficult to determine how it would fit on my expansion tank because the nipple has a ringed barb on the end and the tube is a small diam.

Thanks.

Thanks.

[kuehl]

85911

For the hose that is collapsing, if you can't locate a pre-formed hose you could insert a spring inside the hose.

[85911]

kuehl: Thank you for the good suggestion. Pelican doesn't sell a preformed hose for this application nor does the PET Katalog list one, so I am mail ordering a bunch of metric, braided fuel line today for every generic hose on the car. If this hose doesn't make the 180 without crimping, I'll use a spring as you suggest. I could also make the hose longer to make the 180 a larger diameter, but that would put too much hose in this area.

Update:
I scraped what I thought was JB Weld at the nipple at the top of the filler tube where its leaking and found it was brazing compound. I have never seen brazing compound that color apparently from oxidation. I have brazing rod, so I'll heat it up and maybe add some additional brazing material if necessary and see if the pin hole closes up.

Anybody familiar with the "restrictor", no. 19 on pg. 201-15 of an '86 PET Katalog, part no. A 911 201 263 02?

Also, does anyone have an '85 PET Katalog?

Thanks.

[RLJett]

While the page headers indicate 1986, I believe that katalog is applicable for 84-86 as indicated by the file name and the title shown in window.

https://www.porsche.com/all/media/pdf/originalparts/en/E_911_86_KATALOG.pdf

[85911]

Rob: The Katalog you sent is the same as mine. Thanks for your reply.

[donporfi]

Pelican sells itit

[85911]

donporfi: Thanks. I don't know why, but when I searched Pelican, it didn't come up.

Thanks for your assistance.

[85911]

As I suspected, the new,cloth braided, metric fuel line from Pelican was softer and more pliable than what I had. The kink did not form in the 9mm line attached to the exit of the small, overflow tank. The second picture shows a kink in the original hose.

I brazed over the pin hole in the filler neck and filled up with gas to the top and no leaks and no smell.

Thanks to all for your input.