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2003 Boxster 2.7 Broken Fuel connection
Don't know how, but during the moving / removing of the engine sometime the plastic quick-connect on the end of the fuel line broke! I just noticed it putting it all back together and am VERY thankful I found it before installing engine.
Anyway, it appears that this is completely made to the fuel rails! I can't believe they did that, and it doesn't appear to be the case in earlier cars as mine is a return-less system. Can anyone think of a way to repair / replace this? I'm going to the shop again now to get pictures and to see what options I may have. I can't believe they would have made this all one piece! If anyone has one, please send me a PM. Looking to install ASAP so please let me know what you have and how fast I can get it. BTW - I have GREAT information about the rebuild of a 3 chain engine now. This was BY FAR the most frustrating part of my rebuild (aside from the ridiculously complicated design of the whole engine and the fact that this car only had 24k miles on it before total IMS failure). Thank You, Patrick Harris
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Patrick Harris 1977 Porsche 911S: Racecar build - Follow @ www.patricksporschebuild.blogspot.com 1978 Porsche 911 SC: Petrol Blue, Steel Turbo Body, Black Interior, Sunroof. Another project. 1994 Toyota Supra Twin Turbo, 6 Speed, Hardtop, Baltic Blue (1 of 17). |
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11-24-2012, 06:37 AM
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Join Date: Nov 2012
Posts: 5
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Is there enough space to cut off the other end of the line and slice in high pressure fuel injection hose with rolled edge F.I. hose clamps? OEM fuel systems used to be designed this way with fuel pressures up to 60 psi.
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11-24-2012, 07:56 PM
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You could try used parts...my personal favorites have been Parts Heaven, and dCAutomotive.
PH is in California, I think and dCA is in North Carolina. I've visited dCA recently and they had no less than 50 Boxsters on the floor, being parted out. |
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11-25-2012, 05:15 AM
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Totally "rigged" it until I find a solution. I ground the plastic broken ends flat, cleaned out then tapped the line side with 1/8" NPT and then threaded a 3/8" on the other. I used the loctite "Black Goo" on the threads then capped with epoxy. This is a temporary solution until I get a new quick-connect segment and then splice into hose with double-barb fitting. I just need to get the car fired and broken in for now and had no time to wait any longer (need lift for other cars).
If anyone has one of these fuel rails I only need about 12" of the hose after the quick-connect. Patrick 
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Patrick Harris 1977 Porsche 911S: Racecar build - Follow @ www.patricksporschebuild.blogspot.com 1978 Porsche 911 SC: Petrol Blue, Steel Turbo Body, Black Interior, Sunroof. Another project. 1994 Toyota Supra Twin Turbo, 6 Speed, Hardtop, Baltic Blue (1 of 17). |
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11-26-2012, 06:47 AM
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I got one from DCA. Thanks for the tip.
Question - can the fuel rail be changed without pulling / dropping the engine? Patrick
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Patrick Harris 1977 Porsche 911S: Racecar build - Follow @ www.patricksporschebuild.blogspot.com 1978 Porsche 911 SC: Petrol Blue, Steel Turbo Body, Black Interior, Sunroof. Another project. 1994 Toyota Supra Twin Turbo, 6 Speed, Hardtop, Baltic Blue (1 of 17). |
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11-26-2012, 10:31 AM
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Join Date: Sep 2011
Posts: 68
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I just broke the same fitting today while changing the fuel filter on a 98 boxster. How frustrating!
I want to replace the line but need to figure out what the end at the fuel rail looks like. How much was the line from DCA? |
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12-05-2012, 08:00 PM
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Boxster
