Fuel line leak on return line under car

[massive]

Got an early 944 that has just gone for its yearly check over and they've identified a leak on the hard fuel line that runs underneath the car. It appears to be coming from the return line where it goes up and over the subframe/suspension area at the rear.

Does anyone know the diameter of these lines?

Thinking of the following:

- Replacing section with the flexible braided type with compression connectors

Or

- Getting a shop to create the section in hard tube, again with compression connectors.

[walfreyydo]

Here is a good resource, should be the same regardless of whether its a turbo or NA
https://www.deancent.com/porsche-944-fuel-line-build-and-install/

[BoxsterGT]

Doubt if it is the Return Hardline itself; more likely the crimped Hose connection from the hardline.

The Red Arrow shows where both the Hardlines run up & over the rear suspension.....



Your suggestion to repair this with Hose and Compression Fittings is a good one.

I do this at the front quite often.....



...as the heat from the Motor ages the front hose quite early in its lifetime.

To answer your question, both 8mm and 10mm compression rings are used with the 944.

If you email me I am happy to answer your questions, even though we are across the pond from you.

len.cummings @ verizon.net but without the spaces.

Len

[Monkey Wrench]

for what its worth prior to me buying my early 85it leaked all the gas out from the hose that coects to the fuel tank , not the return line. It was cheap from rock auto. I haven't installed it yet but its a short bendy piece. there is a fuel strainer that it couples to and it has an extreme price, over 100 bucks for a cheesy little plastic screen that threads into the tank.. . I'm thinking of making my own up out of brass fuel screen.
if you remove the fuel sender it might give you a way in to clean the goop out of the bottom of the tank.

id siphon the tank before I started. If yours is also an early version check that hose, if it's not been done replace it. leaking your full tank of gas is pretty dangerous. mine had turned to "goo"

[massive]

Wow, thanks so much for the responses everyone, there's some really good info and experience here.

[massive]

Originally Posted by BoxsterGT

Doubt if it is the Return Hardline itself; more likely the crimped Hose connection from the hardline.

The Red Arrow shows where both the Hardlines run up & over the rear suspension.....



Your suggestion to repair this with Hose and Compression Fittings is a good one.

I do this at the front quite often.....



...as the heat from the Motor ages the front hose quite early in its lifetime.

To answer your question, both 8mm and 10mm compression rings are used with the 944.

If you email me I am happy to answer your questions, even though we are across the pond from you.

len.cummings @ verizon.net but without the spaces.

Len

I'll drop you an email. Thanks

[BoxsterGT]

FIRST, you must determine exactly where this is leaking!

Hope you don't need to drop the rear suspension. That's a huge job.

When you find it, take a photo so we can help / advise.

Len

[joeyfic]

Originally Posted by BoxsterGT

Doubt if it is the Return Hardline itself; more likely the crimped Hose connection from the hardline.

The Red Arrow shows where both the Hardlines run up & over the rear suspension.....



Your suggestion to repair this with Hose and Compression Fittings is a good one.

I do this at the front quite often.....



...as the heat from the Motor ages the front hose quite early in its lifetime.

To answer your question, both 8mm and 10mm compression rings are used with the 944.

If you email me I am happy to answer your questions, even though we are across the pond from you.

len.cummings @ verizon.net but without the spaces.

Len

Hi Len,

I sent you an email regarding a similar issue with my fuel lines.

[BoxsterGT]

David, got your email and answered your question.

However, all this is speculation until you actually find the leak.

The rubber hose connections will fail long before a steel hardline would rust through.

Find the leak, then we can help you.

Len

[walfreyydo]

If you read the guide I posted it will walk you through, in detailed videos, on how to properly replace the hard lines

[BoxsterGT]

Tyler-

Excellent guide to replace the system.

Thank you.