Classic Audi Technical Mech/Tech Engine » Fuel leak, fuel banjos available?

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Old 04-02-20, 04:11 PM   #1
Cynical26
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Default Fuel leak, fuel banjos available?

My coupe has sprung a substantial fuel leak under pressure.

The leak is on the fuel line after the fuel filter. It is so close to the filter that There is not adequate room to cut the damaged section or pipe out and fasten a new copper pipe on. There just wont be enough pipe to fix a new connector on to.

Has anyone had similar and replaced these? Sizes etc. I need would be appreciated.

Thanks


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Old 04-02-20, 06:04 PM   #2
mikes2
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My advice on this is to get a new hose made up and use a compression joint end fitting on the new hose to join up to the old pipe. You can cut the old pipe to get decent metal.

I used Pirtek for the hose. They just copied the old banjo for size and gave me a compression olive for the other end
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Old 04-02-20, 07:25 PM   #3
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Quote:
Originally Posted by mikes2 View Post
My advice on this is to get a new hose made up and use a compression joint end fitting on the new hose to join up to the old pipe. You can cut the old pipe to get decent metal.

I used Pirtek for the hose. They just copied the old banjo for size and gave me a compression olive for the other end
Will 2nd Pirtek as a good company to use..
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Old 05-02-20, 10:47 AM   #4
Cynical26
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Default Fuel leak, fuel banjos available?

Hmmm, ok. Pain in the ass getting the old one off and picking it up from the garage then taking it to Pirtek and then getting it refitted and connected.

If I had a ramp or inspection pit it would be manageable. Unfortunately I don’t so it is at the garage.

Was hoping to order new and get all the required parts together before booking it in.

I’m taking the opportunity to have the fuel pipes replaced at the same time.

Cheers



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Old 05-02-20, 12:43 PM   #5
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That's exactly what happend to me when we were over in France three years ago marshalling on a Classic Car Rally. We were very fortunate to have a "sweeper" van on the event manned by a couple of very expert bodgers who cobbled something together at the side of the road to get us going until we got the job done properly back home.
I used brass compression hydraulic fittings found on the Bay to join to the existing steel pipe (7mm O/D IIRC), a 90 deg bend made from Kunifer so it fitted into the proper rubber support and a short length of ethanol resistant rubber tube to connect to the banjo. My local friendly garage fitted it all together for me because I am now past grovelling on the floor - bad knees!

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Old 07-02-20, 04:03 PM   #6
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So the car is back home untouched by the garage other than the new fuel filter fitted.

Cost me 25 in fuel to get it the 20 miles home as the fuel was just pissing out. Hope no one smoked on the route behind me.

I’m going to take the above advice and get the new banjo fittings made up. Then new copper pipes.

Hope my knuckles and cricked neck survive crawling under the car on the drive


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Old 18-02-20, 10:43 PM   #7
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Any good to you?
https://www.demon-tweeks.com/uk/syte...p-fseefpa2201/
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Old 08-04-20, 09:28 AM   #8
Cynical26
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Default Fuel leak, fuel banjos available?

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Thanks Gaz, that would fit one of the filter ends but not the other.

At the time I was looking to get this fixed I believed the leak was from the banjo on the hardline side.

Pirtek made up a new banjo and braided fuel line with an adaptor down to the 8mm copper pipe for me.

65 later and I’d fitted it. Unfortunately the leak was actually on the other, plastic, pipe end, FML.

Back to Pirtek, new banjo and flexible rubber hose 14 (including 1m of extra hose) and finally the leak was fixed.

Need to investigate properly in future. Doh!

The metal fuel line: This is flexible as Pirtek could not recreationte the old steel/rubber pipe.



The flexible fuel line:



And it all fitted up:



Really need to clean up the fuel pipe routes, replace them all in copper and get more fixing clip rubber guides.

Main thing is it doesn’t leak and runs a whole load better with the new fuel filter.

Just need all the fuel on my driveway to evaporate in this sun now!


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Old 08-04-20, 10:02 AM   #9
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So when it comes to replacing the rest of the rigid fuel lines, the ones that run the length of the car, what is the actual outside diameter of the oem pipe, 7mm or 8mm? Both figures seem to be bandied around, (8mm compression joints seem far more readily available?)
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Old 08-04-20, 02:05 PM   #10
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5/16" or 8mm.

Kunifer is the preferred material as copper cracks with vibrations making it unsuitable for automotive use
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