[s-cars] RE: Fuel Line Recall and then some

[Bob Rossato]

The two piece fuel rail/fuel line was used on the '92-'94 S4.  However, like
the dealer told you, they are no longer available.  In fact my latest ETKA
doesn't even acknowledge the existence of it and only shows the one piece
set up with the line brazed to the fuel rail.  I had to go to an older copy
to find the bolt-on line to make sure I wasn't dreaming it up.

With regard to trying to finding the older set up still in some dealers bin
stock, if you happen to be lucky enough to find it I would imagine it would
be just as expensive as the new version.  You have to buy the old style fuel
rail and the old style bolt-on line, so what have you gained?  If you are
talking about finding one at a junk yard, or from somebody parting out a
car, then it doesn't really matter which one you go with.

I don't believe that your fuel line has failed at the braze joint because
the hard line is brazed to the fuel rail all along the length of the rail.
So, the joint of the tube end to the front of the fuel rail is not stressed
at all.  Let's put it this way, if that's leaking I would suspect that it
was seriously abused by the monkey lad that did the work at the dealer and
you would have a recourse to have them pay for it.  You should be seeing
bent lines for it to leak.  Take off the black plastic injector cover and
you'll be able to see what I'm talking about.

I think it's more likely that you are leaking at the crimp joint between the
stainless braided line and the hard tubing.  Though the dealers comment that
the leak started because you now have "full pressure" to the line is just
bull.  It's possible that it was a result of the tech changing the line and
he may have over stressed it, but you'll never be able to prove that.  Or it
may have been ready to fail anyway and the slight flexing during the R&R of
the other line was enough to push it over the edge.  Keep in mind that the
engine compartment gets quite hot and all the hoses that are attached by
crimps will tend to loosen up and leak due to the rubber lines taking a
compression set under the crimp.  The original fuel that was recalled is an
example, as is the ECU boost line that always pops off the moisture trap on
the '92-'94 S4, and even the headlight washer lines (at least mine did).  At
least with the boost line and the headlight washer lines a simple tightening
of the crimp on hose clamp does the trick.

If the fuel line is leaking at the crimp the only other alternative to
replacing the entire line is to remove it and bring it to a local hydraulic
line supplier.  They should be able replace the stainless braided line with
a new section and crimp it on to the existing ends.  And it will be a hell
of a lot cheaper.  Probably less than $50.  That's the route I would
recommend.  Either that or try to get a used line somewhere.

Bob


> -----Original Message-----
> From: s-car-list-bounces at audifans.com
> [mailto:s-car-list-bounces at audifans.com]On Behalf Of manuel
> Sent: Tuesday, January 13, 2004 8:47 PM
> To: 's-car-list at audifans.com'
> Subject: [s-cars] RE: Fuel Line Recall and then some
>
>
> I haven't physically seen the new leak at the rail yet so I am
> unsure exactly where it is leaking, but, would it be possible to
> weld the crack closed or is the metal too thin? Would welding
> screw up the flow?
>
> When I asked the service writer about obtaining the banjo bolt
> version of the rail he stated that it was no longer available. My
> regular independent mechanic checked is German ETKA and I believe
> he stated that this non-banjo version dated bake to about the '92
> cars, at least the '92 European versions.
>
> Anyone know if the banjo-bolt version would be an acceptable
> swap, assuming I could find one?
>
> -manny
>
>
> Date: Tue, 13 Jan 2004 17:21:12 +0000
> From: bob.rossato at att.net
> Subject: Re: [s-cars] am of course
> To: manuelsanchez at starpower.net
> Cc: , s-car-list at audifans.com
> Message-ID: <011320041721.4687.4a76 at att.net>
>
>
> > So is anyone familiar with this area? Is it not possible to
> > replace this braided hose by itself without replacing the
> > entire fuel rail?  If I am stuck replacing the entire rail, is
> > this an opportunity to upgrade to "something better"?
>
> Unfortunately, on the S6 it's all one piece. The feed line to the
> fuel rail has a short braided section that is crimped to a tube.
> This tube runs all the way to the front of the fuel rail and is
> brazed to the rail.  On the earlier cars, don't know when it was
> swiched over, the tube was bolted to the fuel rail with a banjo bolt.
>
> Bob
> *****************************************