1989 951 leaky fuel return line.

[grendiers]

The rear fuel return line is leaking. Didn't have a flashlight handy, but it's leaking right at the bottom of the rubber line, very spongy too. I've replaced this on a previous 924 turbo, but, easy to see where things start and end. What's one to do here? Is there a hard line up there connected to it?

[kdjones2000]

Been there, done that...

At least one of those lines back there are NLA.

If you are also talking about the hard line, the "proper" way to do it is to get the TWO PIECES from the dealer and replace the entire line from the engine to the tank (the original piece is a single piece, but the replacement is 2 pieces with a coupler). That will set you back $200-300.

Another way is to talk to the person on this forum who will refurbish your current line with near OEM quality fuel hose. You send him your current hose and he will refurbish it and send it back to you.

[grendiers]

Hey Keith, Rennbay has the rubber return line. Just need to figure out where it attaches to the tank, PET was not helpful.

[BoxsterGT]

Howdy,

I can help once you tell us where the leak is coming from specifically.

Lots of options, though some fittings (like the "Fuel Rail Jumper" up front) are unique and require a re-hose of your original.

If your leak is at the return hose that goes from the Chassis Hardline up to the top of the tank, this is also unique, as it is a 10mm hose with a special 10mm x 8mm adapter fitting with 14mm threads.



This is a customer's original fitting.......



A replacement hose was made up that is Metric, E-85 rated, did not require adapters and also is less expensive than most other options.

Please email me for info.

Len at autosportengineering dot com

[kdjones2000]

Look at the "cut" end of the line in Len's picture. That line attaches to the fuel level sending unit up on top of the fuel tank.

Take the clamp off, undo the line and you can pull it out from underneath the car. Getting the new one in there can be "challenging", but possible for us 951 nerds.

Enjoy a cold beverage after swearing at your car one more time....

[BoxsterGT]

If you attach a "fish-line" to it first it helps in getting the replacement back into place. Lots of similar experience with 911 tunnel lines. I use "weed-trimmer" line when doing this at home.

Len

[grendiers]

It's done! With everyone's help, was able to pull the old one out, fished the new one back up, using tape and electrical wire. It was a snug fit, and the pulling-line back up caught on something, hopefully, nothing happened.

Gratuitous shot of the beauty: