Fuel system hose connections

[markcigal]

Does anyone have a good diagram of the fuel system hose connections ? I'm particularly interested in the two hoses that connect to the fuel level sender at the top of the tank. These are accessible from an access hole in the rear hatch area. All the parts diagrams I have looked at do not show these hoses. I'm pretty sure one comes from the fuel pump. One of the hoses to the fuel sender is leaking on my car and I am getting a very strong smell of raw gasoline in the cabin.

[Jfrahm]

One is the fuel return and the other the tank vent.

Also the barbs can get cracked where they are brazed to the sending unit assembly and that will leak fuel when the tank is very full or vapor otherwise.

[Ernie944]

[QUOTE=markcigal;10957329]Does anyone have a good diagram of the fuel system hose connections ? I'm particularly interested in the two hoses that connect to the fuel level sender at the top of the tank. These are accessible from an access hole in the rear hatch area. All the parts diagrams I have looked at do not show these hoses. I'm pretty sure one comes from the fuel pump. One of the hoses to the fuel sender is leaking on my car and I am getting a very strong smell of raw gasoline in the cabin. Here a couple diagrams hope it help

[markcigal]

Thanks for the replies. The line thats seeping is the braided line in the picture. I'm pretty sure it's not a Porsche part. Wondering how difficult it's going to be to replace it. Sure hope I don't have to drop the tank !

[kdjones2000]

That line is the return line from the fuel rail, as you guessed.

In stock form it's not a braided line. It also usually has a zip tie holding it to the vent hose on the top of the tank, making it difficult to replace without at least slightly dropping the tank.

You will not find this in any obvious diagram in PET showing where it goes, since it bridges the sections from fuel tank to fuel system.

The line goes to the hard fuel return line on the body of the car near the torsion bar carrier.

Good luck...

[Jfrahm]

I've replaced that line in a 968 just chasing it from above with new hose, wiring it tight to a temporary M-M fitting.

Mine had deteriorated from fuel oozing from the cracked bulkhead fitting.

[BoxsterGT]

Here is the return line with a Female Euro Flare fitting at the Hardline and a Norma Hose clamp at the Tank.....


I can supply this in E-85 Rated Hose and a correct Norma clamp.

You likely will need a fish line to pull the replacement up in place.

Please email me for details.

Len.Cummings at verizon.net

[BoxsterGT]

There is almost no room between the tank and chassis to route this return line up to the top of the Tank. I am now using the 8mm hose for this in place of the 10mm Hose of the original return, making this a less difficult task.

To connect to the Tank I have a M8 x M10 Adapter. At the Chassis Hardline the Flare fitting is M14 and that is the correct DIN size for 8mm Hose.



Please email me for info.

Len.Cummings at verizon.net

[markcigal]

Len, Many thanks for your perseverance on this. Here is an update on what I've done. After researching parts catalogs and talking to many owners, I found that this part from Pelican Parts was what I needed. https://www.pelicanparts.com/More_Info/PCG209071COEM.htm?pn=PCG-209-071-C-OEM&bt=Y&fs=0&SVSVSI=1017. I disconnected the hose on my car at both ends and hoped to remove it easily. NOT !!! Using a borescope, I found the channel the hose was supposed to be in. Apparently the prior owner had installed the braided hose when the tank was out and realized it was too short. He then set out rerouting it and putting a bunch of fittings and adapters at the chassis hard line end. Despite my best efforts to remove the hose, I could not budge it as it is squashed between the body of the car and the fuel tank.
The good news is, I was able to route the replacement hose through the proper channel and get it hooked up. There are no leaks and I'm back on the road again.
For those of you going through the same thing, I can highly recommend Len's services. Thanks to all who responded to my original post.

[IdahoDoug]

Len,

Thanks for le
ing us know that you have a solution. I am replacing the line from the bottom of the tank to the fuel pump this week, and know others will need replacing not far behind.

Regards,
Doug

[jjeffries]

My 924S project is now equipped with Len’s hoses. My 911SC has been since 2015. It’s the good stuff!

John