Injector Hose Replacement
 

I cut-out dry-rotted hoses and replaced them today. There are a total of 8 for injectors on USA84's, plus 4 other supply or return hoses that need attention. The injector hoses are shown here, others to follow.

Far too many horror stories about these things failing. Very risky to not replace whatever rubber fuel lines, esp. pressurized ones, that your particular year shark has.

I tried to source locally, but decided for several reasons that Rog100 had a far better handle on the situation (special expertise in aircraft hose selection) and have gotten so far kits for three cars. Other suppliers might also have kits.


Attempt at pictures below. Better complete write-ups exist. Since a lot of us are new to the 928's, and we are breathing life into old, tired ones, we best keep vigilant on this problem that some folks don't even realize exists. Am having my dad check is old mercedes cars also for the same type of thing. Ancient hose, pressure, lots of heat, and some ethanol and new-gen additives is a bad combo







http://forums.pelicanparts.com/uploa...1227495192.jpg


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http://forums.pelicanparts.com/uploa...1227495529.jpg

Almost complete----



http://forums.pelicanparts.com/uploa...1227495562.jpg

One to show the cutting of the metal hats...


http://forums.pelicanparts.com/uploa...1227496088.jpg

I cut the old hose in half, then take pliers and tear the hose apart and off the barb leaving the ring more or less intact.

Back burner project is to convert to modern fuel rails and injectors.

The main point here is recognize that there is a serious problem lurking under the hood.

On Pelican, I've seen a number of folks like me ( and you, Mike), new or prospective new owners.

Unlike most, you and I have spent an inordinate amount of time on-line and in shops.

Just want the other guys to know they need to replace hoses with new, high-pressure hose(not normal injection hose), due to the combination effects under these hot V8 hoods.

Mission accomplished.

Chris,

Great pics! I am sure this will help a lot of people. Pictures are always worth a thousand words. Great job!

where to get piece high pressure hose how much you think needed what size

This one looks pretty good, but Roger sells a kit that is known to work. Could be the SAE 30R9 rating is what to look for and the local NAPA etc likely carries something.

***These are my opinions or suggestions, suitability etc. is left for the individual to decide themselves. Specifically I don't know the size required, and fittings as well as hose need to meet high pressure fuel injection specs.

www.************

http://www.autobarn.net/stifi-502.html

Fuel Injection Hose 10', SAE 30R9; 275°F Operating Temp.

Designed for the extremely high temperatures generated by today's fuel injected engines. Temperature range of -29 to +275 Degrees F (302 degrees F intermittent) with a burst pressure rating of 900 psi. This special hose handles leaded, unleaded, alcohol-added, diesel and extended gasolines, resisting sour gas oxidation.

Are those normal clamps going to withstand the high pressures of the Fuel Injection System? If one of those gives way, fuel leak spray to your exhaust manifold are only a few inches away. Could be disastrous to your Shark, and others that might follow.

Ok, here's where I am getting at. It's hard to tell in the pics of the clamps used. They look like normal clamps used in water (radiator, etc) applications. I am guessing that those are the type of clamps that are specific for FI Systems.

I'm going to guess that these are OK:
http://www.ultimategarage.com/frontp...s/ABAMini1.jpg

...and these are NOT:

http://www.ultimategarage.com/frontp...AOriginal1.jpg

Those top clamps are FI clamps. They cost more at the store but they should be fine on the FI hose.

Thanks Chris! Great pics!

I have to do this on my car, have most parts ordered (still need hose). I am pretty much going through my whole fuel system at the moment.

It looks to me that they are the right clamps in the pics.

So can you re-use the hose sleeves (metal hats/rings)? If so, do you just put it on the hose and then push on the hose? Although a FI clamp might be easier for servicing in the future.

Also I have 2 small sections of hose that come out of the fuel regulators (1 on each) and go to the fuel return line. Same goes for these hoses, they need replaced. I believe the hose size is 7.5 mm ID (but have to double check that).

The hose I use in my kits is the correct EFI hose to SAE30R9 and the correct EFI hose clamps.
The injector pressures are pretty low at circa 60 psi (85 psi on CIS cars) and the hose and clamps are rated at much higher than that and burst pressure closer to 1000psi.
My hose kits come with the top and bottom injector seals to complete the job.
You can buy the hose and clamps at NAPA but be sure to use the correct hose and clamps.
The EFI clamps are designed in a way that the edges are curled upwards so they do not cut into the surface of the hose.
An engine set including the feed and return line is $81.
I also have a complete car kit for the early CIS cars.
See Sharkskins web site for details.

I see your helper was hard at work under the table...

I did the same thing i"ll post pics when done. I went ahead a powder coated my fuels rail and injector rings they where looking pretty bad and I looked around and Roger has the best price, service for the buck. Locally not to many shops want to be liable with high pressure fuel lines and the prices were pretty high.

reusing the hats i dont think so there crimped and shoving the hose in not going to hold and more critically wont hold under pressure, would think when fi clamping the clamps both ends that the hats would just be in the way there an expendable item.

I don't know exactly how the hats work, but I "think" I did reuse some of them on one of my cars.

I may do some picts in a few days, but I got my first batch of bits back from plating, including some barbed fuel rails. Wow is plating addictive, more I do, more I want.

Plating? Let's not talk about that you did it and it's addicting. Show us!

Don't be afraid of deleting the metal hats, the barbs themselves retain the hose and the right hose clamps more-than-adequately ensure it.

Do be careful when you remove the old hoses. You don't want to nick the metal barbs. They are softer than a knife, so score the hose, but don't go too deep.

Trying not to be preachy, but guys, don't forget to address the other fuel hoses in the engine compartment, leading into and out-of the injector rails.

The various end hardware is easily re-usable, except the hats typically, for which the clamps are a more secure alternative.

32 V cars have don't have the little short rail hoses, but they do have similar hoses into and out of the injector rails. Somewhere, I have a lot of pictures of replacing them, too, if anybody needs them.

With the loss recently of a couple more cars to fire, most notably the young girl from California's car, we need to keep reminding each other to attack this.

BTW, 944's and 951's of this vintage have very similar issues.

Here's another one of the hoses on the 84 928 that needs replacing:

http://forums.pelicanparts.com/uploa...1242574237.jpg
http://forums.pelicanparts.com/uploa...1242574266.jpg

Carl also just announced a new style fuel rail for those that want to replace the barbed injectors with a modern design. Its not an impossible DIY thing either. If I decide to do it on my hybrid I'll attempt to take picts etc.