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HomeTech Articles > 911 Fuel Fittings Replacement

Pelican Technical Article:

911 Fuel Fittings

Bob Tindel

[Click on Photo]

Figure 1

Figure 2

Figure 3

   I recently replaced the fuel pump in my 1983 911SC in an attempt to repair a tiny but bothersome fuel leak. When the leak persisted after the fuel pump was replaced and all fittings tightened (and retightened), I discovered the true source of the leak. It was a fitting in the fuel pump outlet line that was leaking. When the fitting was removed for repair, it was apparent that the end ferrule connecting the rubber fuel line to the metal line had never been crimped. This fitting had probably been seeping fuel since shortly after the car left the factory. In the accompanying photo, you can see that one ferrule has been crimped while the other has not. (Figure 1)

   One way to repair this defect is to replace the entire fuel line, a costly and laborious procedure. I chose to remove the two ferrules and that section of rubber fuel line, and replace it with a piece of high-pressure fuel line secured with two fuel line clamps. (Figure 2 and Figure 3)

   If you are experiencing a hard-to-locate fuel leak, remove the belly pan from your 911. If the pan is stained on the top side, or if any painted items (fuel pump, steering parts) show any crinkling of the paint, take a careful look at the fuel lines with a good light. You may discover the source of a long-term leak.

Comments and Suggestions:
RickKlem Comments: Bob,
I'm having the same issue and I have had problems finding the banjo fitting that will work with the new fuel line. I have not yet removed my old line and fitting, so I'm not sure if I could reuse the old banjo fitting. Were you able to reusde yours?

June 21, 2011
  Followup from the Pelican Staff: usually the banjo fitting survive the process. That is if you are careful when cutting the clamps off. - Nick at Pelican Parts  

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