broke my metal fuel line

[scott thomas]

Well, it never ceases to amaze me about how the smallest, most
routine job can turn into a nightmare on these cars. The previous
owner of my 200q was good enough to install the fuel filter and
tighten the bolts down so much that I broke the metal line from the
firewall.

Basically, the fix is as follows (this applies to the 200's with that
right angle adapter to the filter inlet, 5k's don't have this):
1.Cut jaged edges off the end of the line with dremel. Grind smooth.
2.Get a flaring tool. Not too expensive, esp if you're going to
return it. I bought a Rigid. $30. I don't fell bad about it, esp
because the threads on the jig wore off. Flare the end, but *very*
gently. It's easy to split the end if you go too far, too fast.
3. Oh yeah, you have to make the line straight. It has two kinks that
net a straight path, but shifted. You have to make it straight, so
the collar nut can fit and you can fit the jig onto it. I put the
collar nut on, would go, so I heated the nut with a propane torch and
put it on the line. Fit perfectly, but be careful. Don't apply the
flame to the fuel line! It helps to remove some of the paint from the
line, so you can turn the nut.

Now, the problem I had was wether or not the flaring would work. The
Audi pipes and adapters are coned inward. The flaring tool flares
outward, like a trumpet. Anyway, the first try at flaring, I split
the pipe. Cut a small amount off. Tried again. Went *really* slow.
Split it slightly, so I just ground it down and a little extra with
the dremel. Installed it and it worked. The filter no longer fits on
the bracket and it inboard about ~2 inches now.

The entire day, I worried about it leaking. I did a few hundred miles
through Jersey with only one problem: it wasn't leaking or dripping,
but just enough to show the metal was exposed to gas. I didn't like
this, but was afraid to tighten it and break the fitting. I did leave
some room for additional tightening, anyhow. I bought a foot of the
rubber fuel injection hose from AutoZone. I bought a brass fitting
 from Home Depot with a barb on one end. The other side would screw
into the right angle adapter. So I could get the right size, I brough
on an old fuel filter with the adapter. Same threads. Anyway, I
bought them just in case I broke the fitting trying to tighten it. I
tightened about 1/5 turn and it started leaking like crazy. Kept
going until I bottomed out and it totally stopped, so I'm relieved.

I was also thinking about going to a wrecker that had a cis vw/audi,
so I can cut the metal fuel ine off the car, but they were all
closed. I'd have used that pipe on the filter and used the rubber
injection hose in between with a bunch of hose clamps on either side.

Anyway, that's how to repair it.

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