Main Tunnel Fuel Lines

[Avanti]

Just installed the main tunnel fuel lines on my 77. I read all of the threads I could find on this but there were no real details on exact routing and securing of the lines in the tunnel.

I see clips/metal tangs inside the access cover in front of the shifter and one in the rear where the shifter bushing is. I assume these hold the lines away from any moving parts.
Is there a clip or tang in between where the shifter is? Some people say to remove the shifter some don't. Not sure if removal of the shifter is for the removal and install of the lines or because there is a place to secure them there.

[steely]

Not sure about the 77, but in my 87 I thought there was was a tunnel within the tunnel if I recall correctly.
It was on the drivers side towards the top of the main tunnel.
This inner tunnel ended several inches in from the ends of the main tunnel, and that is where the main clips were.
I needed to insure that my fuel line didn't interfere with any of the pedal linkage.

[Avanti]

Thanks. Do remember if you had to remove your shifter?

[steely]

Yes, I went nuts, but I was doing several things.
I removed the console and shifter, rear coupler cover, e-brake/auto-heat console, pedal cluster (for a re-build), and the driver's seat.
Most of my pics are underneath the car.
I don't have any of inside the tunnel - bummer.
Here is the only one I found so far of the interior, but you can see the tunnel is exposed.

[Ayles]

I did mine without removing the shifter. You can reach the bendable brackets that hold them in place from the front and rear openings. Use a mirror and flash light, I found it super helpful.

[Tidybuoy]

I'm sure that your '77 has the tunnel-within-tunnel for the fuel lines. The tunnel is on the driver side and is about 4" in, past the rear access hole. At the front, the tunnel ends at about the shifter.

I would remove the shifter because if you have to access the tunnel at the front side, you'll never be able to feed the lines without fiddling around at the shifter hole. For my car, it was easer to fed the lines from the front and it takes a little patience as the fuel lines tend to snag a little bit and you have to work at it a bit.

[Brown747]

Here is my write up when I did it in my 78. HTH

I just did the job of replacing the tunnel lines in my 78...really not a bad job but I will say that I had the engine, shift rod and shifter, and the interior out of the car before starting. The 2 lines, pressure and return were available from our host. I also removed the fuel pump and bracket and removed the T fitting where the brake lines come together just in front of the tunnel lines at the front. You can work around the brake lines but since I am going through the brakes and changing the fluid it made sense to open it up to drain and get myself a little more room. This job would be easier if you had a helper but I was able to do it alone.

I started by disconnecting the lines at the front of the car, pressure line has the banjo fitting that goes on the pump and the return line into the tank, and at the rear of the tunnel where the lines attach that run up to the accumulator and the engine.

Next push out the grommets that go around the tunnel lines at the front and rear of the tunnel (4) I found it easiest to push them with a long screwdriver into the tunnel then retrieve from inside the car.

I replaced one line at a time starting by securing a piece of stout string to the fitting at the back and pulling the line out of the tunnel from the front. Pull a liberal amount of string out at the front then cut it off the old line ensuring that there is enough string remaining at the back to get a grip on when it is time to pull the new line.

Tape over the end of the fitting on the new line so as not to pick up any debris and secure the string. I also lubed the line with some spray silicone. If you have an assistant have them start pulling on the string at the rear while guiding the new line in from the front. Inside the tunnel is another tunnel that runs down the left side that these lines need to run through. It starts maybe six inches back from the front so go inside and check that the line enters that smaller tunnel. The string should help in following the correct path and you can also see where it needs to go by looking in though the shifter hole. Without an assistant I pushed the line in from the front a couple of inches then went inside to take a look to make sure it was going to start down the inner tunnel.
The line will exit the inner tunnel then out through the wall at the end of the tunnel.

Repeat procedure for the remaining line. Clean up or replace the rubber grommets (also available from host) then lube with some silicone spray and reinstall at the front and back. Push them in from the outside. Tighten all fittings and thats it!

HTH Thor

[RFP]

Originally Posted by steely

Not sure about the 77, but in my 87 I thought there was was a tunnel within the tunnel if I recall correctly.
It was on the drivers side towards the top of the main tunnel.
This inner tunnel ended several inches in from the ends of the main tunnel, and that is where the main clips were.
I needed to insure that my fuel line didn't interfere with any of the pedal linkage.

Dan, I'm wondering about your replacement of the fuel lines in your '87. I thought that I had read that cars in and around that year really didn't have fuel line "problems." Did I misunderstand? Thanks,

Rob

[steely]

Hi Rob,
I never heard that for this MY in particular. I was doing it for safety, since I had done the engine lines earlier.

The concern I had and read about was the transition from the line to the rubber hose, particularly in the front tunnel exit near the steering rack, fuel pump area above the cross member. The rubber ages, and I read where some folks tried to simply clamp a new piece of hose there. I understand some have been successful in doing this, but I didn't want to attempt that. I think you will be able to search and find some examples, but I honestly don't know what years they were for.

I never had any real failures, I just did it for piece of mind.
let me know if you have any other questions, although I am sure there are folks here who may know much more about the history.

[steely]

Avanti,
here's a better pic of the interior.
Apologies for the lack of quality and if it presents sideways.

[manbridge 74]

Hmm... must've been doing it wrong all these years.

I only remove the 90 degree ends at front of car with saw and carefully tape the new line to old, butt to butt, with GOOD 3M electrical tape. About 3 or 4 inches on either side and make sure to stretch tape as it goes on. Then pulling from rear of car the old/new line through body. Takes a bit of pulling/twisting but it's not as hard as it sounds.

[frankc]

I did this on my '77 a few years back (I have a thread on this as well). As others have said, there is definitely a channel in the upper left corner of the tunnel where the two lines run. I did have the shifter out for other reasons (handbrake assembly as well), so I had easy access.

[hotaru]

Hi,
I have currently replaced both fuel lines.
I did it with a string. When I was pulling back the new lines - they were hanging up near the entrance to inner tunnel (near the shifter).
I had to unscrew the shifter mount and it gave me enough access to push the line with my fingers into small inner tunnel.
After it was no problems.

[911pcars]

More fuel line install strategies here:
Okay- so I am going to replace my main tunnel fuel lines tomorrow. Any suggestions?

Sherwood

[enzo1]

[ADDvanced]

Does anyone have the part numbers required for doing this? I have a 77 911S

[ADDvanced]

Well, I'm super frustrated right now. I've just spent an hour of my life reading about fuel lines and I still have no friggin clue wtf I need. I'm going to just order some other things I need NOW and try to figure out the fuel lines later, but if anyone had a super straight forward answer on what I actually need to replace with part numbers, I would be super grateful. I cannot figure this out.

Some say you can order the whole thing, but then you're changing the lines in the tunnel. Some say the lines in the tunnel are probably fine, and just change the end. But the ends are 'swedged' on, and the parts may be available. Or maybe not available. There might be newer lines but the fittings could be different.

[GH85Carrera]

Originally Posted by ADDvanced

Well, I'm super frustrated right now. I've just spent an hour of my life reading about fuel lines and I still have no friggin clue wtf I need. I'm going to just order it and try to figure out the fuel lines later, but if anyone had a super straight forward answer on what I actually need to replace with part numbers, I would be super grateful.

Just contact Len. He will make what you need. His email is on most of the fuel line threads. He makes the lines to fit your needs.

[BoxsterGT]

Email me and I will be happy to help you.
Porsche fuel lines are my specialty.
Len.Cummings at verizon.net

[sigchuck]

+1 Len and his tunnel lines. I read up on this extensively before trying it, and it seemed like the most hassle free method was ordering from Len. Also more reasonable than factory parts and ultimately more serviceable since the rubber lines can be removed from the poly tunnel lines.